Experimental Study on PLC–VFD Integration for Real-Time Motor Speed Regulation
Abstract
In industries, controlling the speed of motors accurately is very important for saving energy and improving performance. Old methods like using gears or rheostats are not very efficient and cannot adjust the speed smoothly. To solve this problem, this project uses a Programmable Logic Controller (PLC) and a Variable Frequency Drive (VFD) together to control the speed of a three-phase induction motor. The main goal of this study is to build and test a system that controls the motor speed and checks how the voltage-to-frequency (V/f) ratio affects its working. A small lab setup was made where the PLC gives control signals to the VFD, and different voltage and frequency levels were tested. The readings were compared with Siemens standard drive values to check accuracy. The results showed that the motor works best when the V/f ratio is between 5 and 8 V/Hz. Below this range, the motor loses torque and becomes unstable, and above it, the motor heats up and works less efficiently. This setup helps achieve smooth motor operation, better energy use, and reliable control, making it useful in industries like conveyor systems, water treatment plants, and HVAC systems.
References
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