igbt exciter-based mg set excavator drive overview and ... · comparison thyristor vs...
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DC-EXX MG Control Overview & Field Experience
Slide 12009 TMGE Automation Systems - All Rights Reserved Driving Industry
DC-EXXIGBT Exciter-Based MG Set Excavator DriveOverview and Field Experience
DC-EXXIGBT Exciter-Based MG Set Excavator DriveOverview and Field Experience
Annual MeetingClearwater Florida September, 2009Annual MeetingClearwater Florida September, 2009
TMGE Automation SystemsTMGE Automation Systems
Presented toPresented to
DC-EXX MG Control Overview & Field Experience
Slide 22009 TMGE Automation Systems - All Rights Reserved Driving Industry
Dragline MG Set DC-EXXIGBT System Block Diagram
Dragline MG Set DC-EXXIGBT System Block Diagram
DC-EXX MG Control Overview & Field Experience
Slide 32009 TMGE Automation Systems - All Rights Reserved Driving Industry
Shared Bus IGBT Control Design Goals
• Maximize reliability and safety.• Protect the motor and gen fields from
overvoltage insulation damage.• Protect mechanical equipment.• Use high response regulators and flexible
control to maximize machine productivity.• Minimize maintenance.• Use unique advantages of IGBT
technology over thyristor system.
DC-EXX MG Control Overview & Field Experience
Slide 42009 TMGE Automation Systems - All Rights Reserved Driving Industry
Comparison Thyristor vs IGBTComparison Thyristor vs IGBTThyristor Family of Devices Transistor Family of Devices
Thyristor Reversing Exciter3-ph AC in, DC Out
IGBT Reversing ExciterDC in, Chopped DC Out
DC
From S
ource
[-] VDC
Easy current-controlled turn-on.Difficult, uncontrolled turn off.
Easy voltage-controlled turn-on.Easy voltage-controlled turn off.
DC-EXX MG Control Overview & Field Experience
Slide 52009 TMGE Automation Systems - All Rights Reserved Driving Industry
DC-EXX Comparison with Thyristor ExciterDC-EXX Comparison with Thyristor ExciterQuick Comparison of Structure & FunctionQuick Comparison of Structure & Function
DC-EXXThyristor
Such as DC2000 / Simoreg / AVTRON
+ Windows Toolbox+ Windows Control System Toolbox
+ Standard drive pattern & PLC master+ Function blocks within drive
+ Maximum two Common Transformers+ Individual AC feeders & Drive Transformers
+ Very Low Spares Requirement+ Low Spares requirement
+ No Variation of cards Drive/Drive+ Low Variation of cards Drive/Drive
+ External Isolators for Feedbacks+ Integrated Isolators for most feedbacks
+ Standard drive with PLC individualization+ Fully integrated drive individualized by motion
+ Common group transformer(s)+ Individual Motion Transformers
+ IGBT Based+ Thyristor Based
DC-EXX MG Control Overview & Field Experience
Slide 62009 TMGE Automation Systems - All Rights Reserved Driving Industry
Technical OverviewTechnical Overview
DC-EXX MG Control Overview & Field Experience
Slide 72009 TMGE Automation Systems - All Rights Reserved Driving Industry
Simplified DC-EXX One-Line
DRIVECONTROLLER
DC-EXX MG Control Overview & Field Experience
Slide 82009 TMGE Automation Systems - All Rights Reserved Driving Industry
Overall Typical System One-line [Dragline]Overall Typical System One-line [Dragline]
Common Gen Exciter DC Bus
Common Motor Exciter DC Bus
DC-EXX MG Control Overview & Field Experience
Slide 92009 TMGE Automation Systems - All Rights Reserved Driving Industry
Hoi
stG
en F
ield
s
Hoi
stM
otor
Fie
lds
Sw
ing
Gen
Fi
elds
Swin
gM
otor
Fie
lds
Dra
gG
en F
ield
s
Pro
pel M
ot
Fiel
ds
24 v
dc fa
il-sa
fe P
LC
trigg
er
Dra
g M
ot
Fiel
ds
Dra
gG
en F
ield
s
System One-line [Dragline] with Common PLCSystem One-line [Dragline] with Common PLC
DC-EXX MG Control Overview & Field Experience
Slide 102009 TMGE Automation Systems - All Rights Reserved Driving Industry
One Motion & Loop DetailOne Motion & Loop Detail
24 v
dc fa
il-sa
fe P
LC
trigg
er
24 v
dc fa
il-sa
fe P
LC
trigg
er
DC-EXX MG Control Overview & Field Experience
Slide 112009 TMGE Automation Systems - All Rights Reserved Driving Industry
Sync and Soft Start ExcitationSync and Soft Start Excitation
600 amp600 ampPR
OFI
BUS
PRO
FIBU
S
DC-EXX MG Control Overview & Field Experience
Slide 122009 TMGE Automation Systems - All Rights Reserved Driving Industry
Gen Field Supply DC Shared Bus Chopper vs SCR Gen Field Supply DC Shared Bus Chopper vs SCR
Bottom Line: One GF AC MCC Feed vs 4One Transformer vs 4
DC-EXX MG Control Overview & Field Experience
Slide 132009 TMGE Automation Systems - All Rights Reserved Driving Industry
DC Chopper “Kilowatt Source” ConceptDC Chopper “Kilowatt Source” Concept
Field kW= I2 x Rhot
kW in = Total Field kW
Amps = kw/volts
Motion Qty kW Data Sheet 36H. IRMS EaIndividual
Exciter RMS
Field Watts per
Gen
Bus DC watts
watts x qty gens
Hoist 6 1254 926224RA-SH2 18.9 113.4 2244.7 13467.9
Drag 1 3 1254 926224RA-SH2 18.9 56.7 2244.7 6734.0
Drag 2 3 1254 926224RA-SH2 18.9 56.7 2244.7 6734.0
Swing 6 836 925638RA-SH6 16.8 100.8 3663 21978.0
"SUM" = 327.6 total bus watts = 48913.8
Min DC Bus Volts = 550 exciter effic = 95%
total Bus DC Amps = 93.6 otal converter load kW 51488
Generator Data
1. Power In = total power of load / efficiency
2. DC amps = bus kw / bus volts3. DC Amps NOT = total of DC
load amps4. Transformer load = kw at 0.95
PF, 0.98 efficiency
PWM Chopper Output varies
average voltage to control current
DC-EXX MG Control Overview & Field Experience
Slide 142009 TMGE Automation Systems - All Rights Reserved Driving Industry
Motor Field Supply DC Shared Bus
Chopper vs SCRLarge Dragline Example Sync
Motors AND Motion Motor Exciters on Same Bus
Bottom Line:• One AC MCC Feed vs 2• One Transformer vs 2,
total kva 400 vs 1100 kva
DC-EXX MG Control Overview & Field Experience
Slide 152009 TMGE Automation Systems - All Rights Reserved Driving Industry
Crowbar Connected Gen Field DB Resistor Crowbar Connected Gen Field DB Resistor
•No contactors = No Maintenance
•Crowbar trip set at level high enough to avoid false trips.
•Takes full advantage of new exciter capabilities –controlled DB first, crowbar is emergency backup
24 v
dc fa
il-sa
fe P
LC
trigg
er
DC-EXX MG Control Overview & Field Experience
Slide 162009 TMGE Automation Systems - All Rights Reserved Driving Industry
Three Stop ModesThree Stop Modes1. Master switch to Neutral – normal stop2. Motion LE stop – IGBT exciters and
controller operate to bring motions to stop under full control, then LE opens
3. “Emergency” – lost power, lost fuse, or ESTOP – LE opens, Static Crowbar
connects DBR to gen fields for fast decayshorts motor fields for slow decay.
DC-EXX MG Control Overview & Field Experience
Slide 172009 TMGE Automation Systems - All Rights Reserved Driving Industry
Controlled Braking During LE StopControlled Braking During LE Stop
??
UNCONTROLLEDDBR - LE STOP
DC-EXX CONTROLLED
LE STOP
DC-EXX USES STOREDFIELD ENERGY
TO MAINTAIN EXCITATION WITH AC POWER REMOVED
DC-EXX MG Control Overview & Field Experience
Slide 182009 TMGE Automation Systems - All Rights Reserved Driving Industry
Exciter System Drive Controller RoleExciter System Drive Controller Role
• Drive Controller & Software is included in system for mode selections, tapered current limits, loop unbalance, etc.
• Excavator supervisory PLC[OEM or supplied as part of upgrade]
Sends references, start-stop and hard contact control signals to drives Receives feedbacks over ProfibusHas access to global data buffer for offboard monitoring or onboard reporting
DRIVEPLC
SupervisoryPLC
H S D1 D2
H S D P
T1
T2
LE
O-HMI
M-HMI
Gen Field DC Bus
Mot Field DC Bus
DC-EXX MG Control Overview & Field Experience
Slide 192009 TMGE Automation Systems - All Rights Reserved Driving Industry
Drive Controller Functionality - GeneralDrive Controller Functionality - General• High speed regulation functions in drive exciter• Outer loop and excavator functionality in HS Drive
Controller like…Speed and torque limitsLoaded bucket controlSwing gearing quadrant transition
• Basic Settings done with simple windows tool• Drive Controller communicates with DL supervisory
PLC over HS Profibus
DC-EXX MG Control Overview & Field Experience
Slide 202009 TMGE Automation Systems - All Rights Reserved Driving Industry
Drive Controller Example Functionality -Showing Drive Controller & Supervisory PLC Split
Drive Controller Example Functionality -Showing Drive Controller & Supervisory PLC Split
EXAMPLE PAGE 1 OF ABOUT FOUR
DC-EXX MG Control Overview & Field Experience
Slide 212009 TMGE Automation Systems - All Rights Reserved Driving Industry
Exciter Configuration WinNew ToolExciter Configuration WinNew Tool• Digitally Configurable• Windows-based
simplified PC tool• Few basic parameters• Outer current and upper
voltage limits• Protective limits for
fields• All other dynamic
performance set by Drive Controller
DC-EXX MG Control Overview & Field Experience
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WinNew Exciter Performance TestingWinNew Exciter Performance Testing• Instantly shows effects of settings on operation
•Digitally Configurable on PC tool for display on PC screen
•Any parameters can be displayed, scaled.
•Simple controls
DC-EXX MG Control Overview & Field Experience
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Controller HMI Maintenance / Setup ScreensController HMI Maintenance / Setup Screens
Range from Simple to Elaborate
DC-EXX MG Control Overview & Field Experience
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Circuit & Component DetailsCircuit & Component Details
DC-EXX MG Control Overview & Field Experience
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DC ConvertersDC Converters• Three-phase, up to 600 VAC
in• Up to 600 volts DC out• 350 or 750 amp frames for
all excavator applications• “Soft-on” for charging DC
bus capacitors• Ruggedized for excavator
use.• Built in Absorption chopper
feeds remote resistors for field protection during power loss.
DC-EXX MG Control Overview & Field Experience
Slide 262009 TMGE Automation Systems - All Rights Reserved Driving Industry
Installed AD / DC Converter &Control Power Supply
Installed AD / DC Converter &Control Power Supply 1. AC / DC Converter
2. 435 volt input, 600 vdc output to common bus
3. Two ratings, 350 or 750 amp.
4. 24 volt DC Power supply, 120 – 240 vac input tolerance for stability
1. AC / DC Converter
2. 435 volt input, 600 vdc output to common bus
3. Two ratings, 350 or 750 amp.
4. 24 volt DC Power supply, 120 – 240 vac input tolerance for stability
24 VDC Power Supply
24 VDC Power Supply
AC / DC ConverterAC / DC Converter
DC-EXX MG Control Overview & Field Experience
Slide 272009 TMGE Automation Systems - All Rights Reserved Driving Industry
Chopper Exciters Chopper Exciters • Three Basic Frames: 150, 300 &
600 amps• 300 or 600 volt DC bus feed• Included dv/dt filter produces
insulation-friendly output for motor and generator fields.
• Basic Current limits, gains, lead-lags, high speed protections, & parameter scalings all included within exciter.
• Capacitors are film-foil type, not electrolytic type.
Not sensitive to temperature extremesNo “wearout” or timed replacement or failures
DC-EXX MG Control Overview & Field Experience
Slide 282009 TMGE Automation Systems - All Rights Reserved Driving Industry
DC-EXX ChopperFront View & Display
DC-EXX ChopperFront View & Display
DC-EXX MG Control Overview & Field Experience
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DC-EXX Power ConnectionsDC-EXX Power Connections
DC Bus Input [+] and [-]
DC Bus Input [+] and [-]
Exciter Output [U] and [V]
Exciter Output [U] and [V]
DC-EXX MG Control Overview & Field Experience
Slide 302009 TMGE Automation Systems - All Rights Reserved Driving Industry
Modules & FootprintsModules & Footprints
150 AExciter
300 AExciter
350 AConverter
Crowbar
9 H x 6 Wx 6 D
600 AExciter
750 AConverter
DC-EXX MG Control Overview & Field Experience
Slide 312009 TMGE Automation Systems - All Rights Reserved Driving Industry
Output dv/dt Filter Output dv/dt Filter Simple dv/dt filter limits peak voltage output to motor and generator fields to equal or lessthan thyristor legacy systems.
Traditional Thyristor Exciter460 volts 3 ph AC In
IGBT Exciter460 volts 3 ph AC In
No dv/dt filter
IGBT Exciter460 volts 3 ph AC In
With dv/dt filter
Field Coil [s]
DC-EXX MG Control Overview & Field Experience
Slide 322009 TMGE Automation Systems - All Rights Reserved Driving Industry
Voltage & Current IsolatorsVoltage & Current Isolators1.24 – 230 volts ac /
dc powered
2.Fixed gain settings:
• +/- 50, 100, 150 mv = +/- 10 VDC out
• +/- 600, 750, 1200 v = +/- 10 VDC out
1.24 – 230 volts ac / dc powered
2.Fixed gain settings:
• +/- 50, 100, 150 mv = +/- 10 VDC out
• +/- 600, 750, 1200 v = +/- 10 VDC out
DC-EXX MG Control Overview & Field Experience
Slide 332009 TMGE Automation Systems - All Rights Reserved Driving Industry
Dual Trigger Mode Crowbar ModulesDual Trigger Mode Crowbar Modules
• Discharges energy safely from generator or motor fields
• Bi-directional – for use with motor or generator exciters
• Fires either on cell voltage [>1000 v] or by drop out of fail-safe relay.
DC-EXX MG Control Overview & Field Experience
Slide 342009 TMGE Automation Systems - All Rights Reserved Driving Industry
Current and Voltage IsolatorsCurrent and Voltage Isolators• 24 – 260 volts AC / DC
powered• 1200 volts input for loop
voltage feedback• 100 Millivolt for shunt
feedback.• DIN rail mounted• Rugged – used in rail service• Worldwide distribution
DC-EXX MG Control Overview & Field Experience
Slide 352009 TMGE Automation Systems - All Rights Reserved Driving Industry
Rx3i Automation ControllerRx3i Automation Controller 1. High speed [<1 millisec scan]
2. All outer loop and excavator functions
3. Powered by stabilized 120 VAC
4. Minimal discrete I/O
5. Profibus DP communication with drives & excavator supervisory PLC
1. High speed [<1 millisec scan]
2. All outer loop and excavator functions
3. Powered by stabilized 120 VAC
4. Minimal discrete I/O
5. Profibus DP communication with drives & excavator supervisory PLC
DC-EXX MG Control Overview & Field Experience
Slide 362009 TMGE Automation Systems - All Rights Reserved Driving Industry
1. Run-Stop2. Analog I/O1. Run-Stop2. Analog I/O
Controller I/O to Drive Interface
Controller I/O to Drive Interface
DC-EXX MG Control Overview & Field Experience
Slide 372009 TMGE Automation Systems - All Rights Reserved Driving Industry
Touch Screen Setup HMITouch Screen Setup HMI
1. Touch screen setup HMI
2. Individual motion monitor and control for test flexibility
3. Allows training as well as operational testing
1. Touch screen setup HMI
2. Individual motion monitor and control for test flexibility
3. Allows training as well as operational testing
DC-EXX MG Control Overview & Field Experience
Slide 382009 TMGE Automation Systems - All Rights Reserved Driving Industry
Setup HMI Top LevelSetup HMI Top Level
1. Top level monitor screen
2. Each “Button”shaped readout brings more detail as it is touched
3. Alarm and logic status
1. Top level monitor screen
2. Each “Button”shaped readout brings more detail as it is touched
3. Alarm and logic status
DC-EXX MG Control Overview & Field Experience
Slide 392009 TMGE Automation Systems - All Rights Reserved Driving Industry
Setup HMI Special Control ModesSetup HMI Special Control Modes
1. Test Modes included as needed
2. Serves as mode input to controller.
1. Test Modes included as needed
2. Serves as mode input to controller.
DC-EXX MG Control Overview & Field Experience
Slide 402009 TMGE Automation Systems - All Rights Reserved Driving Industry
Setup HMI Special Simplified MonitorSetup HMI Special Simplified Monitor
1. Real time values displayed
2. Touching the icon allows setting of parameter.
1. Real time values displayed
2. Touching the icon allows setting of parameter.
DC-EXX MG Control Overview & Field Experience
Slide 412009 TMGE Automation Systems - All Rights Reserved Driving Industry
Setup HMI Monitor and SetupSetup HMI Monitor and Setup
Profibus Signal MonitorProfibus Signal Monitor
Setting Touch ScreenSetting Touch Screen
Setting Error ProtectionSetting Error Protection
DC-EXX MG Control Overview & Field Experience
Slide 422009 TMGE Automation Systems - All Rights Reserved Driving Industry
Setup HMI Alarm ScreenSetup HMI Alarm Screen
1. Time stamped
2. First fault, first listed.
1. Time stamped
2. First fault, first listed.
DC-EXX MG Control Overview & Field Experience
Slide 432009 TMGE Automation Systems - All Rights Reserved Driving Industry
Field InstallationsField Installations
DC-EXX MG Control Overview & Field Experience
Slide 442009 TMGE Automation Systems - All Rights Reserved Driving Industry
First SystemsFirst Systems1. BMA DRE-08 8050 with W Electrics Blackwater Mine• Mechanical refurbishment• New PCR, Complete Rewire• 45 days total lights out to boom up in June 08
2. BMA 1370W – Saraji DRE-083. Blair Athol 1370W, with soft start4. Ensham 8050 Emerald Mine – dragline underwater!5. Rix Creek 305M Crawler Dragline6. BMA Saraji 8050 DRE-137. Ten new 182M shovels, 1 new 8750 DL systems plus 3 more
upgrades in process
1. BMA DRE-08 8050 with W Electrics Blackwater Mine• Mechanical refurbishment• New PCR, Complete Rewire• 45 days total lights out to boom up in June 08
2. BMA 1370W – Saraji DRE-083. Blair Athol 1370W, with soft start4. Ensham 8050 Emerald Mine – dragline underwater!5. Rix Creek 305M Crawler Dragline6. BMA Saraji 8050 DRE-137. Ten new 182M shovels, 1 new 8750 DL systems plus 3 more
upgrades in process
DC-EXX MG Control Overview & Field Experience
Slide 452009 TMGE Automation Systems - All Rights Reserved Driving Industry
Equipment as Configured for Dragline Installation
Equipment as Configured for Dragline Installation
DC-EXX MG Control Overview & Field Experience
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Motor & Gen AC / DC Converter
Motor & Gen AC / DC Converter
• 435 VAC 3 Phase in 600 VDC out
• 350 amp 6-pulse diode• 3 thyristor legs for soft
on, overcurrent protection.
• Includes energy absorbing chopper
• Feeds two overhead buses at cabinet top
• 435 VAC 3 Phase in 600 VDC out
• 350 amp 6-pulse diode• 3 thyristor legs for soft
on, overcurrent protection.
• Includes energy absorbing chopper
• Feeds two overhead buses at cabinet top
DC-EXX MG Control Overview & Field Experience
Slide 472009 TMGE Automation Systems - All Rights Reserved Driving Industry
Motor & Gen Exciter CabinetsMotor & Gen Exciter Cabinets• 600 VDC in• Pulse-width DC Volts
out• Identical 150 amp
rated exciters, all motions
• All commands and feedbacks by Profibus
• Includes input reactors and output filter
• Static Crowbar means no contactors except drag-propel field selection
• 600 VDC in• Pulse-width DC Volts
out• Identical 150 amp
rated exciters, all motions
• All commands and feedbacks by Profibus
• Includes input reactors and output filter
• Static Crowbar means no contactors except drag-propel field selection
DC-EXX MG Control Overview & Field Experience
Slide 482009 TMGE Automation Systems - All Rights Reserved Driving Industry
Sync Motor CabinetSync Motor Cabinet
• 300 Amp Exciter [with same control as 150 amp]
• Fed from 600 volt DC source for high forcing
• Traditional three-pole application contactor
• Fed from DC bus above cabinet
• 300 Amp Exciter [with same control as 150 amp]
• Fed from 600 volt DC source for high forcing
• Traditional three-pole application contactor
• Fed from DC bus above cabinet
DC-EXX MG Control Overview & Field Experience
Slide 492009 TMGE Automation Systems - All Rights Reserved Driving Industry
Overhead DC BusOverhead DC Bus • 600 VDC, two busses• Independent feed for motor
and gen exciters• Feed for each exciter is
dropped by cable into enclosure
• Excess energy absorbed by converter braking chopper.
• Safety Provisions:• Disconnects• Discharge contactor• Voltage presence lights
• Voltage held to 725 volts even when AC feed is lost
• 600 VDC, two busses• Independent feed for motor
and gen exciters• Feed for each exciter is
dropped by cable into enclosure
• Excess energy absorbed by converter braking chopper.
• Safety Provisions:• Disconnects• Discharge contactor• Voltage presence lights
• Voltage held to 725 volts even when AC feed is lost
DC-EXX MG Control Overview & Field Experience
Slide 502009 TMGE Automation Systems - All Rights Reserved Driving Industry
Later Panel Lineup – New PCRLater Panel Lineup – New PCR
Covered DC BusCovered DC Bus
Complete Swing Motion
Complete Swing Motion
Sync Motor ExciterSync Motor Exciter
Sync Motor Contactor
Sync Motor Contactor
Dragline Drop-In Power Control Room
Dragline Drop-In Power Control Room
DC-EXX MG Control Overview & Field Experience
Slide 512009 TMGE Automation Systems - All Rights Reserved Driving Industry
Swing Cabinet DetailsSwing Cabinet Details
Connections to DC Bus
Connections to DC Bus
Static Crowbar & DB Switch
Static Crowbar & DB Switch
Isolation SwitchIsolation Switch
dv/dt Filter Reactor
dv/dt Filter Reactor
DC Decoupling Reactors
DC Decoupling Reactors
DC-EXX MG Control Overview & Field Experience
Slide 522009 TMGE Automation Systems - All Rights Reserved Driving Industry
Sync Cabinet DetailsSync Cabinet Details
Isolation SwitchesIsolation Switches
dv/dt Filter Reactors
dv/dt Filter Reactors
DC Decoupling Reactors
DC Decoupling Reactors
300 Amp Exciters300 Amp Exciters
Field Application Contactors
Field Application Contactors
DC-EXX MG Control Overview & Field Experience
Slide 532009 TMGE Automation Systems - All Rights Reserved Driving Industry
DB, Sync Discharge and Absorption ResistorsDB, Sync Discharge and Absorption Resistors
•Gen field decay “dynamic brake”
•DC bus absorption, sized by duty cycle.
•Gen field decay “dynamic brake”
•DC bus absorption, sized by duty cycle.
DC-EXX MG Control Overview & Field Experience
Slide 542009 TMGE Automation Systems - All Rights Reserved Driving Industry
MG Set Shovel Control MG Set Shovel Control
• Ten Bucyrus 182M 10 Meter3 bucket
• Indian Market• Cab-Mounted PLC
Control • 4 Motions, dipper
trip and converter in 72 inch W x 20 inch deep enclosure!
Main DC-EXX ControlMain DC-EXX Control Main DC-EXX ControlDoors Open
Main DC-EXX ControlDoors Open
DC-EXX MG Control Overview & Field Experience
Slide 552009 TMGE Automation Systems - All Rights Reserved Driving Industry
Testing & Startup ExperienceTesting & Startup Experience
DC-EXX MG Control Overview & Field Experience
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Full Onboard Installation Testing GoalsFull Onboard Installation Testing Goals• Demonstrate equipment safety and protection of
dragline & rotating gear.• Demonstrate effectiveness of shared bus supply• Demonstrate system regulator and exciter
responses.• Demonstrate high speed controller and
communication effectivenessin coordinating motionsIn sync motor excitationIn dragline digging and propel operational modes
DC-EXX MG Control Overview & Field Experience
Slide 572009 TMGE Automation Systems - All Rights Reserved Driving Industry
Equipment Protection: Field Surge VoltageEquipment Protection: Field Surge Voltage
DESIGN GOAL:Limit Peak Volts on field insulation to equal or less than 780 volts, the typical peaks for a thyristor exciter.
DESIGN GOAL:Limit Peak Volts on field insulation to equal or less than 780 volts, the typical peaks for a thyristor exciter.
EXAMPLE TEST RESULTS:With Bus at 548 VDC, peak volts 688.EXAMPLE TEST RESULTS:With Bus at 548 VDC, peak volts 688.
DC-EXX MG Control Overview & Field Experience
Slide 582009 TMGE Automation Systems - All Rights Reserved Driving Industry
Shared Bus Supply Test ResultsShared Bus Supply Test Results• Gen bus has surplus energy only 10-
20% or so of time.• Motor field and sync motor bus has
even lower surplus power percent.• High-speed static DB-Contactor /
Crowbars are vital to this type system.• Conclusion: diode converter with
absorber chopper- resistor is effective.
DC-EXX MG Control Overview & Field Experience
Slide 592009 TMGE Automation Systems - All Rights Reserved Driving Industry
Motion Regulator Setup & ResponsesMotion Regulator Setup & Responses
Required Responses Actual Responses
DRAG 40 - 80 radians 74 radians
HOIST 40 - 80 radians 47 radians
Required Responses Actual Responses
DRAG 40 - 80 radians 74 radians
HOIST 40 - 80 radians 47 radians
Drive Controller in Boom Raise Mode
Drive Controller in Boom Raise Mode
LOOP 1 & 2 AMPSLOOP 1 & 2 AMPS
LOOP 1 GEN VOLTSLOOP 1 GEN VOLTS
LOOP 2 GEN VOLTSLOOP 2 GEN VOLTS
EXAMPLE CURRENT REGULATOR TESTINGEXAMPLE CURRENT REGULATOR TESTING EXAMPLE MOTION STALL TESTINGDRAG SHOWN
EXAMPLE MOTION STALL TESTINGDRAG SHOWN
DRAGDRAG
HOISTHOIST
DC-EXX MG Control Overview & Field Experience
Slide 602009 TMGE Automation Systems - All Rights Reserved Driving Industry
X-Y RecordingsX-Y Recordings
DRAGDRAG PROPELPROPELNormal Walk ModeNormal Walk ModeDrag max speed 850 RPM
Payout max speed 1105 RPMDrag max speed 850 RPM
Payout max speed 1105 RPM
DC-EXX MG Control Overview & Field Experience
Slide 612009 TMGE Automation Systems - All Rights Reserved Driving Industry
X-Y RecordingsX-Y Recordings
HOISTHOIST SWINGSWINGHoist speed 883 rpm
Lower speed 1087 rpmLoop #2 outside Limits
Hoist speed 883 rpmLower speed 1087 rpm
Loop #2 outside Limits
RMS & Temps Indicated OverloadRef Reduction Software relieved load on Motors
RMS & Temps Indicated OverloadRef Reduction Software relieved load on Motors
DC-EXX MG Control Overview & Field Experience
Slide 622009 TMGE Automation Systems - All Rights Reserved Driving Industry
Experience & Lessons Learned - 1Experience & Lessons Learned - 1
• Minimal equipment failures related to individual hardware modules.
• Second installation: Found need for crowbars on sync motorsFound need for self powered energy absorption chopper for larger systems [3 or 4 MG sets].
DC-EXX MG Control Overview & Field Experience
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Lessons Learned - 2Lessons Learned - 2
DC-EXX MG Control Overview & Field Experience
Slide 642009 TMGE Automation Systems - All Rights Reserved Driving Industry
Other Things LearnedOther Things Learned
• Aux transformers run much cooler• Per motion controlled stop easier
on gearing, etc• Very few and common spares and
fuses a “Plus”• Moving all but 4 to 6 parameters
into PLC makes exciters simple
DC-EXX MG Control Overview & Field Experience
Slide 652009 TMGE Automation Systems - All Rights Reserved Driving Industry
Present StatusPresent Status• Eighteen complete systems sold and in
various stages of manufacture & installation.+7 upgrades+11 new excavators
• 6 draglines operational as of September 2009.
• One new system with IGBT armature supply soft starting.
DC-EXX MG Control Overview & Field Experience
Slide 662009 TMGE Automation Systems - All Rights Reserved Driving Industry
Summary – DC-EXXExcavator MG Control System
• Early results are encouraging.• IGBT technology gives real
advantages for MG control.• Drive controller adds flexibility.
DC-EXX MG Control Overview & Field Experience
Slide 672009 TMGE Automation Systems - All Rights Reserved Driving Industry
Thanks!Thanks!
Office Location:
TM GE Automation Systems, LLC1325 Electric Road Roanoke, VA 24018 [Office]
2060 Cook Drive Salem VA, 24153 [Mailing]USA
TEL: +1-540-283-2000; FAX: +1-540-3283-2005www.tmeicge.com