afe igbt ac drives for b.e. 495 shovels - wmeawmea.net/technical papers/afe drives for b.e. 495...
TRANSCRIPT
AFE IGBT AC Drives For Bucyrus 495BII Shovels
The Western Mining Electrical Association
Albuquerque, New Mexico
November 16, 2000
Frank G. Wickert
Bucyrus International, Inc.
BUCYRUS INTERNATIONAL
� GE STATIC DC DOM+ ( 301M 204M )� SINCE 1992 FIFTEEN MACHINES
� GE STATIC DC DC2000 ( 595-B )� SINCE 1997 FIVE MACHINES
� SIEMENS GTO ( 495-B 395-B 295-B )� SINCE 1989 SIXTY MACHINES
� SIEMENS IGBT ( 495-B )� SINCE 1999 FOUR MACHINES SOLD
BUCYRUS INTERNATIONAL
� ACUTROL SERIES III
� INSULATED GATE BIPOLAR TRANSISTORS (IGBT)
� FUSELESS, SNUBBERLESS INVERTERS
� ACTIVE FRONT END
� INTEGRAL DIAGNOSTIC COMPUTER
BUCYRUS ACUTROL III IGBT
� DISTRIBUTION SYSTEM COMPATIBILITY
� MAINTAINABILITY
� SUPERIOR PERFORMANCE
AFE
� Active Front End
� Replaces traditional forward/regenerative rectifier
� Same hardware as inverter
� IGBT based
� Modular design
� Lower harmonics
� Leading PF capability
495BII Shovel
Propel 1
Cap.Overvoltage
protection
PWM Inverters
Motions
Swing
500 HP
Crowd
700 HP
700 HP
2240 HP
Swing
500 HPSwing
Hoist
1400 V
1400 V
1400 V
1400 V
1400 V
1400 V
Precharge circuit
Rp
PT
PTPT
L reactor
Rp
Rd
Rg
Rg
Rg
Rg
Propel 2 700 HP1400 V
XFO 1Ground
detection circuitDischarge
resistorVoltagesensor
XFO 2
Short-circuitdiode
CbD1
Cg
AFE
L reactor
L reactor
L reactor
7200 Volts - 60 Hz6600 Volts - 50 Hz
480 Volts - 60 Hz380 Volts - 50 Hz
Acutrol III (IGBT)
IGBT Active Front End Block Diagram
VSS SIBAS Control
Precharge
Input Contactor / CB Input Reactor
AFE DC Bus Cap. Inverter
ACMotor
AFE Stagger
� Pulse pattern = 15
� Pulse frequency = 15 (60) = 900 Hz
� Stagger = 360(fund.)/{(pulse f)(# AFEs)]
� Stagger = 360(60)/[(900)(4)] = 6 degrees
AFE IGBT Firing
� Triangular modulation signals @ 900 Hz
� Sine wave reference signal
� Comparative circuit used for switching
� DC bus & PF regulator adjust amplitude of reference to set actual points of firing
AFE Stagger
-1.5
-1
-0.5
0
0.5
1
1.5
0 50 100 150 200 250 300 350 400
degrees
sinwt
afe1
afe2
afe3
afe4
AFE Stagger
-1.5
-1
-0.5
0
0.5
1
1.5
0 10 20 30 40 50 60
degrees
sinwt
afe1
afe2
afe3
afe4
AC sourcevoltage
AFEreactor
AFE AC inputvoltage
I Vsource
Vreactor
Vafe
Vreactor
Vsource
Vafe
I
Vsource
Vreactor
Vafe
I
PF=1
PF leading
PF lagging
-1.5
-1.0
-0.5
0.0
0.5
1.0
1.5
-1.5 -1.0 -0.5 0.0 0.5 1.0 1.5
Regenerative Watts - Motoring Watts (pu)
Lag
ging
Var
s -
Lea
ding
Var
s (p
u)
A - 81% Line VoltageB - 90% Line VoltageC - 100% Line VoltageD - 110% Line VoltageE - 0.9 Leading PF
A
BC
D
E E
F
0.0
%
0.5
%
1.0
%
1.5
%
2.0
%
2.5
%
0
6
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
126
132
138
144
Harm
on
ic Ord
er h
Harmonic Current [ % ]
0.00%
0.05%
0.10%
0.15%
0.20%
0.25%
0.30%
0.35%
0
6
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
126
132
138
144
Harm
onic Order h
Harmonic Current [ % ]
IGBT has fast reaction to changes in current.
Eliminates all fuses.
Active Front End
Operates at a Unity Power Factor and <5% total harmonic distortion.
Siemensunitized welded electrical skid cabinet.
Increased rigidity and strength.
Enhanced diagnostic computer with multi-language capability.
Acutrol III (IGBT)
AC Drive System
Benefits
495BII Shovel
Simple, routine maintenance.
No brush orcomutatormaintenance.
No flashover.
Fewer internal connections.
Shorter rewind lead time.
Lower rewind costs.
Acutrol III (IGBT)
BenefitsAC- IGBT Benefits over
DC Drive
495BII Shovel
AC Drive System No UPS
(Uninterrupted Power Supply).
Safe shutdown on power loss is inherent.
PLC in drive control.
Eliminates the PLC cabinet.
Remote start panel in operators cab.
Control and logic signals are sent to PLC via remote I/O. (operators controls, encoders, MCC, Lube Drive Motor temperature and brake monitoring)
Acutrol III (IGBT)
Benefits
495BII Shovel
MAINTAINABILITY
� RUGGED AC MOTOR
� IMPROVED TACHGENERATOR
� IMPROVED SKID CONSTRUCTION
� UPS ELIMINATED
� REGEN RESISTOR ELIMINATED
� GREATER MTBF
MOTOR MAINTAINABILITY� NO BRUSHES OR
COMMUTATORS
� IMPROVED DIGITAL SHAFT MOUNTED SPEED SENSORS
� ARMORED CABLE TO MINIMIZE COMMON MODE NOISE AND GROUND CURRENT
Maximized Reliability
Speed Sensor Evolution
Spieth element or clamp for mounting on
shaft.
Spieth element
Acutrol II (GTO) & Acutrol III (IGBT)
Sealed bearings and labyrinth shaft seal.
720 pulses per revolution instead of
1024.
Clean disk with compressed air.
Replaceable electronic module.
Maximized Reliability
Cabinets bolted and welded on a common skid.
Acutrol II (GTO)
Wire harness.
Tested as a complete unit.
Digital controls without temp. drift
requires notune-up.
Dust-proof control cabinet.
Maximized Reliability
Single welded Enclosure
Acutrol III (IGBT)
Separation of clean and dirty air
Wire harness.
Tested as a complete unit.
Digital controls without temp. drift
requires notune-up.
Dust-proof control cabinet.
SYSTEM MAINTAINABILITY� DRIFT FREE DIGITAL
ACUTROL CONTROL
� RUGGED WELDED ELECTRICAL SKID WITH CLEAN AND DIRTY AIR ISOLATION
� REMOTE PLC I/O FOR FEWER CONNECTIONS
POWER ELECTRONICS
� IGBT FOR INVERTER AND AFE
� PROTECTION IS ACHIEVED WITHOUT FUSES OR SNUBBER CIRCUITS
� GATE DRIVERS ARE LOW POWER COMPARED TO SCR�S AND GTO�S
� FEWER COMPONENTS MEANS IMPROVED RELIABILITY
IGBT MODULE
IGBT: 3300 V, 1200 AmpMotor Voltage : 1400 V
Acutrol III (IGBT)Maximized Reliability
IGBT's (Insulated Gate Bipolar Transistor)used as power switches.
No snubber circuits or fuses required.
Transitor needs only low power gating signal to turn on and off.
Same IGBT power modules for Active Front End (AFE) and inverter with "plug-in" design.
INSIDE AN IGBT MODULE
COMPATIBILITY
� ACTIVE FRONT END ( AFE )
� FULL REGENERATION
� UNITY POWER FACTOR
� LESS THAN 5% TOTAL HARMONIC DISTORTION
� PLUS 10% MINUS 20% INPUT VOLTAGE
Distribution System CompatibilityAcutrol III (IGBT)
Power Factor 1.0 .8 lead - .8 lag
Input Voltage +10% +10%-20% -20%
THD 11% <5%
RPC YES NO
DC Static AC-IGBT (w/AFE)
CONTROL ELECTRONICS
� ACUTROL III DIGITAL CONTROL FOR BOTH INVERTER AND AFE
� PROVEN LOW SPEED CONTROL STRATEGY
� MIL SPEC COMPONENTS FOR LOW TEMPERATURE APPLICATION
� PARAMETER SELECTABLE MACHINE ADJUSTMENTS
CONTROL CONCEPT
CONTROL ELECTRONICS
� OVERCURRENT TRIPS MINIMIZED BY RIDE THROUGH ABILITY
� PLC, ACUTROL III CONTROL, DIAGNOSTIC COMPUTER, COMMUNICATION VIA PROFIBUS
DIAGNOSTIC COMPUTER
� INTEGRAL WITH ACUTROL III CONTROL AND MACHINE PLC
� SIMPLIFIED GRAPHICAL INTERFACE FOR RAPID PROBLEM DETECTION
� TOUCH SCREEN FOR EASY NAVIGATION
� BUILT IN TROUBLESHOOTING MANUAL
DIAGNOSTIC COMPUTER
DIAGNOSTIC COMPUTER
DIAGNOSTIC COMPUTER
DIAGNOSTIC COMPUTER
REMOTE DIAGNOSTICS
IGBT SUMMARY
� PRODUCTIVITY ADVANTAGES OF SERIES I AND II MAINTAINED
� NO ROUTINE MAINTENANCE WITH AC MOTORS
� IMPROVED TACH RELIABILITY
� IMPROVED DIAGNOSTICS
� BEST COMPATIBILITY OF ANY STATIC DRIVE
From Past Successesto Future Innovations
Hydraulic Crowd BenefitsReduced Impact Loading
No Crowd Rope or Rack & Pinion Maintenance
Ease of Maintenance
Environmentally Friendly
795B795B
Power Unit Located on
Machinery Deck
Eliminated traditional
Crowd Machinery
No Handle or Rack Lube Required
795-B DECK PLAN
Electrical�AC - IGBT (Insulated Gate Bipolar Transistor)
�Electrical Control Room
�Rugged Skid Structure
�Fuseless Drive
�Swing & Hoist motors are interchangeable with 495B
�No Uninterrupted Power Supply (UPS)
�Regenerates to Line
�Diagnostic Computer
Standard 3Ph/60Hz/7200v Option to 15,000v
Rapid reaction time
Carry-over capability through electronics
Additional power regulated through a
�United Power System�
Consolidation of components
Reduced vibration input
495B with upgrades
Soft-DumpLatchless Dipper
Benefits
Unique DesignPatent Applied For
Improved MTBF and MTTR
2-Pass Load 240 Ton Haul Trucks
Reduced Truck and Operator ImpactNo Latch Lever No
Latch BarNo Latch Keeper No Trip Rope
12� Dia. Cylinder
Metered Dump
Optimized Hinge Location
Provides an Additional 2.5 Feet of Dumping Height
CL
Bucyrus Loading
Advantage
42�2� Min(12.85m)
(Tail Swing = 39�)
59�2� Max(18.03m)
CAT 797CAT 797
17� window forhaul truck positioning.
Large positioning window for reduced haul truck spotting
times.
Existing shovel designs require
alignment under boom point.
Moving Into The Next Generation
0
20
40
60
80
100
Feet
195B 295B 495B 595B 795B795B795B795BTHE NEXT THE NEXT THE NEXT THE NEXT
GENERATIONGENERATIONGENERATIONGENERATION
395B