11/17/05
Improved Control Algorithm for
Infrared Paper Dryers
ECE 480 Senior Design Review
November 17, 2005
Blake Peck
Rob Schaerer
Jay Hudkins
Carl Lee
Instructor: Dr. Joe Law
Technical Advisor: Dr. Joe Law
Sponsor: Potlatch Corporation, Pulp and Paper Division
11/17/05
Presentation Outline
• Background
• Previous Design Work
• November 3rd Tour
• Design Concept 1
• Design Concept 2
• Design Concept 3
• What’s Next?
11/17/05
Background - Paper Manufacturing
• Uniform Moisture Content = Good Paper• IR Dryers:
– Divide paper sheet into “zones”– Monitor zone moisture content– Adjust zone heat
11/17/05
Background – Control System
Paper Line Control Rack
Control Room
Power Computer
Operator Computer RS 485
CP
U C
ard
Moisture SensorPhase
Monitoring
Gate Drivers/
ThyristrorsIR Lamps
Trigger C
ard 1
Trigger C
ard 2
Trigger C
ard 3
Trigger C
ard 4
11/17/05
Background - Potlatch Installation
• Potlatch purchased IR Dryers from Compact Engineering Ltd.
• Present Control algorithm doesn’t consider cumulative effect of individual lamp loads
• Some Total Harmonic Distortion (THD)• High Crest Factor (CF)
11/17/05
Previous Design Work
• Spring 05’ design team– Created improved control algorithm
• Decreases THD and Crest Factor
– Tested algorithm with scaled system model– Provided demonstration of concept– Provided architecture for power computer
11/17/05
November 3rd Tour – Big Picture
• High level perspective of control hardware • Understanding of physical locations
11/17/05
November 3rd Tour – Big PicturePOWER COMPUTER
Operating Console
Operating Computer
RS-485 Communications
Board (SERT-485)
Pass Through Board
Phase Monitor Unit
(PMU)
Gate Drivers
Thyristors
Key
boar
d
Mon
itor
Siz
e P
ress
Moi
stur
e S
enso
r (
RS
-232
)
Cal
enda
r M
oist
ure
Sen
sor (R
S-2
32)
Control Room Rack Room Power Control Cabinet PCC1 (1 of 2)
PCC1 (a-c)
Port 5
Port 6
Port 4
Phase Xmfrs
Pass Through Board
Phase Xmfrs
Phase Monitor Unit
(PMU)
CPU Card
Power Supply
Digital Trigger Card
Digital Trigger Card
Digital Trigger Card
Digital Trigger Card
PLC Interlock Computer
I/O/E
ther
net
Gate Drivers
Thyristors
PCC1 (d-f)
?
RS-485 RS-232
11/17/05
November 3rd Tour – Cabinets
Power Cabinet Control Cabinet
11/17/05
November 3rd Tour – PMU
• Phase monitoring unit– Detects zero crossings – Build or Purchase
11/17/05
November 3rd Tour – PMU
• Layout– 30 hours @ $30/hour = $900
• Fabrication– $400
• Total = $1300
11/17/05
November 3rd Tour – Knowledge Gained
• Arcom manufactures Power Computer, CPU card, and SERT 485 board
• Thyristor connection details
• RS 485 hardware connections
• Phase transformer specifications
11/17/05
Conceptual Design – Current System
• Issues:– Some THD
– High CF
11/17/05
Conceptual Design – Design 1
• Pro’s:– Least expensive solution
for paper machine #1– Less new hardware design– Majority of current system
left in tact
• Con’s:– More reverse engineering– Stuck with power
computer architecture– Modify Compact’s power
computer code
11/17/05
Conceptual Design – Design 2
• Pro’s:– Less reverse engineering
– High quality power computer documentation
– Lower long term cost
• Con’s:– Higher development cost
– More design engineering
– More testing required
11/17/05
Conceptual Design – Design 3
• Pro’s:– Little to no reverse
engineering
– Develop new communication protocol
– Easily managed user defined power levels
• Con’s:– Most development cost
– More development time
– Require extensive testing
11/17/05
What’s Next? – Project Tasks
• Detailed knowledge of 1st team’s work– Jay with Rob
• Operator and Power Computer code– Blake with Carl
• Hardware design– Carl with Blake
• Impact of 3-phase power– Rob with Jay
• Test and verification plan– Carl with everyone
• System documentation and organization – Rob with Jay
11/17/05
What’s Next? – Contact Points
• End of conceptual design – Mid November
• Approval of proposal– Mid January
• System built for testing– End of February
• System testing complete– End of March
• Installation– Next shutdown in April
11/17/05
Acknowledgements
• Joe Law• Jerry Spencer• Team #1
11/17/05
Questions?