How to Troubleshoot “ERR10” Fault on an Inverter? The “ERR10” fault code on an inverter typically indicates an overcurrent fault—one of the most common issues encountered during inverter operation. When this error occurs, follow these steps to troubleshoot and resolve the problem: 1. Stop the Machine Immediately for Inspection First, cut off the inverter’s power supply. Wait a few minutes, then restart it to check if the fault is occasional (i.e., a one-time glitch). 2. Inspect the Motor and Load Check if the motor is running under overload or if the load has increased suddenly. Verify whether the motor windings are short-circuited or grounded; use a multimeter to measure the motor’s winding resistance for confirmation. Examine if mechanical transmission components are jammed, as this can cause the motor to stall (and trigger the overcurrent fault). 3. Check Wiring Connections Inspect the wires connecting the inverter to the motor for looseness, short circuits, or unintended grounding. Check if terminal blocks are oxidized or have poor contact, as both issues can disrupt current flow and trigger false faults. 4. Verify Parameter Settings Confirm that the inverter’s parameters match the motor’s specifications, such as the motor’s rated current and rated voltage. Mismatched parameters often lead to overcurrent. Check if the acceleration time is set too short. If so, extend the acceleration time parameter appropriately—rapid acceleration can overload the motor and trigger ERR10. 5. Inspect the External Environment Check if the ambient temperature around the inverter is too high, if its heat dissipation system is functioning effectively, and if the cooling fan is working properly. Overheating can impair current regulation and cause false overcurrent alerts. Check for electromagnetic interference (EMI) in the area, as EMI can disrupt the inverter’s internal circuits and lead to incorrect fault codes. 6. Troubleshoot Internal Hardware Faults If all the...

Why Are Single-Phase Input Inverters Unsuitable for High-Power Equipment? Single-phase input inverters are unsuitable for high-power equipment, primarily due to limitations in input capacity, current stress, DC bus ripple, grid compliance, and cost-effectiveness. These constraints make it challenging to deliver stable, efficient, and compliant operation when handling high power loads. Key Reasons Overview Limiting Factor Specific Performance Impact on High-Power Operation Input Power Supply Capacity & Current Single-phase power supplies have inherent limits on the current and apparent power they can deliver. High-power equipment demands large currents, which often causes single-phase circuits to overload and experience significant voltage drops. Rectifier Bridge & Component Stress Single-phase rectification only uses two phases for conduction, leading to higher peak and average currents. This creates excessive current stress on rectifier bridge arms and capacitors, requiring significant derating (typically to around 2/3 of the rated capacity). DC Bus Ripple Single-phase rectification results in fewer voltage zero-crossing events, generating larger voltage ripple on the DC bus. To mitigate this, larger capacitors and more robust heat dissipation systems are needed—both of which increase the inverter’s size and cost. Three-Phase Grid Imbalance & Harmonics High-power single-phase loads often disrupt three-phase grid balance and cause harmonic levels to exceed regulatory limits. Additional harmonic suppression and imbalance correction measures become necessary, raising operational, maintenance, and compliance costs. Efficiency & Heat Dissipation High currents and excessive bus ripple lead to greater power losses and heat generation within the inverter. This reduces overall efficiency, lowers long-term reliability, and requires more powerful cooling solutions to prevent overheating. Cost & Practicality Scaling single-phase inverters for high power requires oversized components and cooling systems. The resulting unit cost and physical size end up being comparable to three-phase alternatives, making single-phase options economically unviable. Why Not Simply “Scale Up” Single-Phase Inverters? Component Stress & Cooling Limits:...

How to Determine Which Inverter to Choose Based on Load Characteristics In industrial scenarios, the core of inverter selection lies in “matching load characteristics”—different loads vary significantly in torque, speed, impact resistance, and other properties. Improper selection can lead to low equipment efficiency, frequent failures, or even burnout. Starting from the classification of load characteristics, this article clarifies the corresponding selection logic for DreamWe inverters by aligning with the core requirements of various loads, and includes typical application cases to help users accurately match the right inverter solution. 1. First, Clarify the Core Classification of Load Characteristics: 3 Basic Types The key distinction between load characteristics lies in the “relationship between torque and speed“. The most common industrial loads fall into three categories, and their traits directly define the functional requirements for inverters:   Load Type Core Characteristic (Torque-Speed Relationship) Typical Application Scenarios Constant Torque Load Torque remains consistent and independent of speed (load torque stays nearly unchanged regardless of speed); high starting torque is required during startup Lifting equipment (cranes, elevators), conveyors, extruders, mixers Constant Power Load Power remains stable, and torque is inversely proportional to speed (higher speed leads to lower torque; torque is extremely high at low speeds) Lathes, milling machines, grinders (metal cutting), winders (late-stage winding) Quadratic Law Load Torque is proportional to the square of speed, and power is proportional to the cube of speed (torque is low at low speeds and rises rapidly at high speeds) Fans, water pumps, cooling towers, ventilators 2. Matching DreamWe Inverters Based on Load Characteristics: Scenario-Specific Selection Guide Different loads have distinct demands for an inverter’s “torque response speed, overload capacity, speed regulation range, and energy-saving features”. As such, it is essential to select DreamWe inverter models in a targeted manner: 1. Constant Torque Loads: Prioritize DreamWe Inverters with “High Overload Capacity and Fast Torque Response”...

Advantages of DTC Technology in Lifting Equipment DTC (Direct Torque Control) technology, as an advanced inverter control method, enables the direct and precise regulation of motor torque and flux. It effectively addresses the pain points of traditional control technologies—such as slow response speeds, poor stability, and low energy efficiency—when applied to lifting equipment. Its core advantages can be elaborated from five key dimensions: operational efficiency, control precision, adaptability to working conditions, system maintenance, and economic benefits, as detailed below: 1. Operational Efficiency: Fast and Accurate Torque Response to Reduce Idle Waiting The core requirement of lifting equipment is frequent start-stops and rapid load changes (e.g., lifting/lowering heavy objects, adjusting operating positions), which demands an extremely high dynamic torque response speed.DTC technology eliminates the need for complex coordinate transformations (such as the rotational transformation used in traditional vector control) and the simplification of motor mathematical models. Instead, it calculates and controls electromagnetic torque directly in the stator coordinate system, achieving a dynamic response speed of < 2ms—far faster than the tens of milliseconds required by traditional control systems.   Practical Scenario: When lifting steel bars or cement at construction sites, DTC technology allows cranes to respond instantly to “lifting” commands. It quickly increases torque to meet load requirements, avoiding the waiting time caused by the “slow start” of traditional systems. Compared with traditional control methods, operational efficiency can be improved by approximately 30%, making DTC particularly suitable for high-frequency, fast-paced lifting operations. 2. Control Precision: Precise Speed and Position Regulation to Ensure Operational Safety In precision lifting scenarios (e.g., transporting high-value equipment, fragile components, or installing precision instruments), “zero sway and high-precision positioning” are critical.DTC technology uses stator flux orientation and directly adjusts stator flux and electromagnetic torque via a two-position “bang-bang controller,” enabling:   Precise Low-Speed Control: Even when heavy objects move at an extremely...

How to Enhance the Robustness of Vector Control and Direct Torque Control In AC motor speed control systems, Vector Control (VC) and Direct Torque Control (DTC) are two mainstream high-performance control strategies. However, they differ in sensitivity to parameter perturbations, load disturbances, and external interferences. Targeted optimizations are required to improve their robustness—defined as a system’s ability to maintain stability and control accuracy under disturbances. Below is a detailed breakdown of “core challenge analysis” and “strategy-specific optimization methods,” combined with technical pathways and theoretical details, to systematically explain robustness enhancement solutions. I. First, Clarify: Core Robustness Challenges of VC and DTC The root cause of insufficient robustness lies in the “deviation between the control model/target and the actual system state.” The core pain points of the two strategies differ and must be addressed specifically:   Control Strategy Core Control Logic Robustness Weaknesses Typical Disturbance Scenarios Vector Control (VC) Based on “field orientation,” it decomposes the stator current into an excitation component (id) and a torque component (iq), which are independently controlled via PI regulators. It relies on accurate motor parameters (e.g., stator resistance Rs, rotor resistance Rr, leakage inductance σL, mutual inductance Lm) to build a mathematical model. 1. Strong parameter dependence: Rotor resistance Rr changes with temperature (e.g., Rr can increase by 2–3 times at a temperature rise of 200°C), and mutual inductance Lm changes with magnetic saturation—both directly causing field orientation deviations.2. Dynamic lag of the current loop: Traditional PI regulators have a slow response to sudden load changes, easily leading to overshoot or steady-state errors.3. Grid voltage disturbances: Voltage sags or imbalances cause coupling between id and iq, disrupting decoupled current control. Long-term motor operation (parameter drift), frequent sudden load changes (e.g., machine tool cutting, elevator start/stop), low-voltage grid fluctuations. Direct Torque Control (DTC) Does not rely on precise field orientation. It directly selects...

How to Further Optimize the Performance of Vector Control (VC) and Direct Torque Control (DTC)? Vector Control (VC, also known as Field-Oriented Control, FOC) and Direct Torque Control (DTC) are the two core technologies for high-performance AC motor control in current applications. Although they differ in control logic—VC is based on “field orientation-current decoupling,” while DTC relies on “direct torque/flux hysteresis regulation”—their core goals for performance optimization are consistent: improving dynamic response speed, enhancing steady-state control accuracy, strengthening anti-interference capability, and reducing torque ripple and energy loss. Below is a systematic explanation of performance improvement solutions, divided into “common optimization strategies” and “targeted optimization strategies.” I. Common Optimization Strategies for Both Vector Control (VC) and Direct Torque Control (DTC) The performance bottlenecks of both control technologies are directly related to “signal sensing accuracy,” “control algorithm robustness,” and “hardware execution efficiency.” These bottlenecks can be addressed through the following universal methods: 1. Optimize Motor State Observation and Feedback Accuracy The measurement/estimation accuracy of core motor state signals—such as speed, rotor position, stator current, and flux—serves as the “foundation” of control performance. Errors in these signals directly lead to field orientation deviations (in VC) or inaccurate torque calculation (in DTC), resulting in torque ripple.   Selection of High-Precision Sensors: Prioritize photoelectric encoders with a resolution of 17 bits or higher (suitable for servo scenarios) or resolvers (ideal for high-temperature, high-vibration industrial/automotive environments) instead of low-precision Hall sensors. For current sampling, use high-precision shunt resistors (±0.1%) or Hall current sensors paired with ADC chips of 16 bits or higher to reduce sampling noise. Improvement of Observer Algorithms: If high-precision sensors cannot be used due to cost or installation space constraints, optimize sensorless observers: At low speeds: Replace traditional sliding mode observers with the “high-frequency injection method” to reduce flux observation errors (especially for VC...