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

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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)

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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

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November 3rd Tour – Big Picture

• High level perspective of control hardware • Understanding of physical locations

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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

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November 3rd Tour – Cabinets

Power Cabinet Control Cabinet

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November 3rd Tour – PMU

• Phase monitoring unit– Detects zero crossings – Build or Purchase

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November 3rd Tour – PMU

• Layout– 30 hours @ $30/hour = $900

• Fabrication– $400

• Total = $1300

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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

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Conceptual Design – Current System

• Issues:– Some THD

– High CF

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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

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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

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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

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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?