new dc-exx shared bus igbt mg control; bill horvath, tmgs - nov 07

ONE COMPANY. A WORLD OF SOLUTIONSTM GE Automations Systems

Western Mining Electrical Association – Fall 2007New DC-EXX Shared Bus IGBT MG Control

New IGBT Exciter- Based MG Set Excavator Drive

New IGBT Exciter- Based MG Set

Excavator Drive

Presenter

Presentation Notes

This presentation is comprised of nine sections. An introduction to GE – a great way to begin a presentation by focusing on our employees and our commitment to our customers. A history of performance – a brief overview of the our consistent financial performance Innovation – highlights our heritage of innovation from Edison to the present Our capabilities – examples of GE structure, processes and organization that allow us to meet the needs of our customers and serve them better Our commitment – highlights GE’s efforts in all aspects of social responsibility Our businesses – an overview of each business with an example of a product or service they provide and cross-business technology examples Growth – an overview of our growth strategy and Imagination Breakthroughs, with an IB example from each business Our brand – an overview of the value of the Monogram and the “imagination at work” campaign Wrap up slides – one slide to summarize the GE story, and another to include necessary trademark information



MG Set DC Drives -

A History

19951987

19671960

1950’s1940’s

2007

Full Digital ControlHybrid PLC/Analog

Static Analog Amplistat

AmplidyneThree Field Control

Shared BusIGBT Control



DC EXXDC EXX•

DC is part of a wide product family from TMEIC-GE

•

Robust DC Conversion for armature supply to 20,000 HP

•

New complete drives and DFE retrofit

BUT, high performance, single field Thyristor [SCR] based

MG set control

not part of development plan



ProfibusRef & control

DCMotor

DCGen

ACMotor

IGBT Sync FldRegul. &Supply

MVACInput

Excavator MG Set DC-EXX IGBT System Block Diagram

Generator FieldIGBT PWM

Exciter Regulator

Diode rectifiers

Motor FieldIGBT PWM

Exciter Regulator

One per motion

One per motion



Gen Field Control Design GoalsGen Field 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.



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 Comparison with GE DC2000 or other Thyristor Exciter

DC-EXX Comparison with GE DC2000 or other Thyristor Exciter

Quick Comparison of Structure & FunctionQuick Comparison of Structure & FunctionThyristor

Such as DC2000 / Simoreg / AVTRONDC-EXX

+ Thyristor Based + IGBT Based

+ Individual Motion Transformers + Common group transformer(s)

+ Fully integrated drive individualized by motion + Standard drive with PLC individualization

+ Integrated Isolators for most feedbacks + External Isolators for Feedbacks

+ Low Variation of cards Drive/Drive + No Variation of cards Drive/Drive

+ Low Spares requirement + Very Low Spares Requirement

+ Individual AC feeders & Drive Transformers + Maximum two Common Transformers

+ Function blocks within drive + Standard drive pattern & PLC master

+ Windows Control System Toolbox + Windows Toolbox



Simplified DC-EXX One-LineSimplified DC-EXX One-Line



Overall Typical System One-line [Dragline]Overall Typical System One-line [Dragline]

Common Gen Exciter DC Bus

Common Motor Exciter DC Bus



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



Gen Field Supply DC Shared Bus Chopper vs SCR Gen Field Supply DC Shared Bus Chopper vs SCR

Motion Qty kW Data Sheet 36H.. IRMS Ea Individual Exciter RMS

Field Watts per Gen

Bus DC watts

watts x qty gens

Calc kVA Practical Selection

Hoist 6 1254 926224RA-SH2 18.9 113.4 2244.7 13467.9 70.5 75

Drag 1 3 1254 926224RA-SH2 18.9 56.7 2244.7 6734.0 35.3 50

Drag 2 3 1254 926224RA-SH2 18.9 56.7 2244.7 6734.0 35.3 50

Swing 6 836 925638RA-SH6 16.8 100.8 3663 21978.0 62.7 100

total bus watts = 48913.8 203.7 275 Total kva

4 transf.

Min DC Bus Volts = 550 exciter effic = 95%

total Bus DC Amps = 93.6 Net total converter load kW 51488Converter PF 0.95 savings!Converter eff. 0.98

Transformer kVA = kW/(pf*eff) 54.2 Use 60 Primary Supply Volts = 440

AC Feeder Amps 71.1

Generator Converters and ExcitersGenerator Data [from published designs] KVA Equiv SCR Xfmr

Bottom Line: One GF AC MCC Feed vs 4 One Transformer vs 4



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 / buss volts3.

DC Amps NOT = total of DC load amps

4.

Transformer load = kw at 0.95 PF, 0.98 efficiency

PWM Chopper Output varies

average voltage to control current



Motor Field Supply DC Shared Bus Chopper vs SCRMotor Field Supply DC Shared Bus Chopper vs SCRMotor Field Converter [no diversity included except propel at 40% when digging]

QtyMotor Model[start with ' & enter as text]

Series Connected IRMS

single ckt, 6 fields

Individual Exciter DC RMS

Amps

Per Motor Field watts [propel at

40%]

Total Field Watts

kVA Contrib to SCR Type

Exciter

Hoist 6 826 25.0 150 5270.3 31622 48.5

Drag 6 826 25.0 150 5270.3 31622 48.5

Swing 6 822 20.0 120 4287.9 25727 38.8Propel 2 824 33.0 66 3485.3 6971 21.3 No Effect

157.2

Not Applic Use 175kVA

IGBT = FALSE total bus watts = 95941

exciter effic = 95%

Min DC Bus Volts 550 total Motor Source Bus DC Amps for converter rating = 183.6

Net total converter load kW 100991Converter PF 0.95 savings!Converter eff. 0.98

Required Transformer Transformer kVA = kW/(pf*eff) 106.31 Use 125 Primary Supply Volts = 440 kVA

Converter AC line Amps 139.5

Comparison Total DC Motor Field Exciter

Transformer kVA for SCR System

IGBT Fed Sync motor field Contribution From Below{Check Box at left if IGBT Exciter is used] USE IGBT Sync Exc? USE IGBT Sync Exc?

Case 1.

Only Motion Motor Exciters on Bus

Sync Motor separately fed

Bottom Line: 28% Smaller Field Transformer



New Choice: IGBT vs Thyristor Sync Motor ExcitationNew Choice: IGBT vs Thyristor Sync Motor Excitation

dv/dtFilter

Sync MotDC-EXX

dv/dtFilter

Sync MotDC-EXX

IGBT Sync Motor Excitation System[2 motors shown]

EE

ThyriteTypical

ThyriteTypical

TRADITIONAL THYRISTORSYNC EXCITATION

IGBT SYNC EXCITATIONFED FROM MOTION MOTOR

FIELD DC BUS



IGBT vs Thyristor SystemIGBT vs Thyristor System

Sync Motor Qty SYNC HP

SYNC Field IRMS Ea

SYNC Field Watts at 120 vdc Typical Hot Drop

Single Exciter DC RMS Amps

AC Line Sec Amps

Transf Sec Volts 3-ph

VoltsBus KVA

Transformer Size for SCR

System

Motor 1 3 4000 185 22200 555 452.88 240 188.3 Use

Motor 2 0 NA 0 0 0 240 0.0 200AC Supply Volts = 440 Total KVA for SCR Exciter Transformer = 188.3 kVA

Primary AC Amps = 247.0

Sync Motor Qty SYNC HP

SYNC Field IRMS for

Each Field Exciter

Peak Exciter amps at 1.6 P.U. peak

field

SYNC Field Watts at 120 vdc Typical Hot Drop

Total SYNC Field

Watts on DC Motor Exciter

Bus

Added kVA to source feed

transformer at typical pf and

efficMotor 1 3 4000 185 296 22200 66600 71.5 savings!Motor 2 0 NA 0 0 0 0 0.0

Total Sync Motor DC Watts [Contributes to Motor Source Bus Load Above] 66600 71.5

Thyristor Sync Motor Field Exciters with one exciter for all sync motor fields Fed from separate sync Converter & Transformer

IGBT Sync Motor Field Exciters with exciter one per sync motor field Fed from Motion Motor DC Converter & Transformer



Motor Field Supply DC Shared Bus Chopper vs SCRMotor Field Supply DC Shared Bus Chopper vs SCR

Case 2.

Sync Motors AND Motion Motor

Exciters on Same Bus

Motor Field Converter [no diversity included except propel at 40% when digging]

QtyMotor Model[start with ' & enter as text]

Series Connected IRMS

single ckt, 6 fields

Individual Exciter DC RMS

Amps

Per Motor Field watts [propel at

40%]

Total Field Watts

kVA Contrib to SCR Type

Exciter

Hoist 6 826 25.0 150 5270.3 31622 48.5

Drag 6 826 25.0 150 5270.3 31622 48.5

Swing 6 822 20.0 120 4287.9 25727 38.8Propel 2 824 33.0 66 3485.3 6971 21.3 No Effect

157.2

66600 Use 175kVA

IGBT = TRUE total bus watts = 162541

exciter effic = 95%

Min DC Bus Volts 550 total Motor Source Bus DC Amps for converter rating = 311.1

Net total converter load kW 171096Converter PF 0.95 savings!Converter eff. 0.98

Required Transformer Transformer kVA = kW/(pf*eff) 180.10 Use 200 Primary Supply Volts = 440 kVA

Converter AC line Amps 236.3

Comparison Total DC Motor Field Exciter

Transformer kVA for SCR System

IGBT Fed Sync motor field Contribution From Below{Check Box at left if IGBT Exciter is used] USE IGBT Sync Exc? USE IGBT Sync Exc?

Bottom Line: One AC MCC Feed vs 2 One Transformer vs 2, total kva 200 vs 400 kva



Common Bus MG Set Exciters Making of a “Green”

System

Common Bus MG Set Exciters Making of a “Green”

System

•

Fewer Exciter transformers [2 vs 6] & Kva total load reduced to 42%

•

Aux transformer load and losses reduced

•

Cleaner harmonics – dual transformers form

delta-wye with partial cancellation

KVA load for SCR Transformers 549.1KVA load for DC-EXX Transformers -234.3

Difference KVA load DC-EXX vs Thyristor 314.8Power Factor of kVA Load Difference 0.70

KW load for difference 220.4Transformer efficiency 0.985

Exc Transf Kw saved 3.31Aux transformer kW saved 3.31

Total kW saved 6.61Cost of electricity $0.065

Cost / Hour $0.430Hours per year 8000

Saved per year $3,438

EXAMPLE LARGE DRAGLINE6 H, 6 D, 6 SW



Three Stop ModesThree Stop Modes1.

Master switch to Neutral –

normal stop

2.

Motion LE stop –

DC-EXX

operates to bring motion 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.



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



Field Circuit & Dynamic Brake Designs No Contactors –

Dual Mode Trigger Crowbar DBR

Field Circuit & Dynamic Brake Designs No Contactors –

Dual Mode Trigger Crowbar DBR

1.

For regular LE Stop, LE Opens, DC-EXX control quickly brings drive to stop within VA Limits

2.

Under true E-stop, lost fuse, or exciter fault, field decay & braking set by crowbar & DBR only..

Open Feeder for LE Stop, E-Stop or

Fault

Crowbar connected DBR with NO LE or DB contactors but with

good DB performance



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



Drive PLC Functionality -

GeneralDrive PLC Functionality -

General•

High speed regulation functions in drive exciter

•

Outer loop and excavator functionality in PLC like…Speed and torque limitsLoaded bucket controlSwing gearing quadrant transition

•

Basic Settings done with simple windows tool•

Drive PLC communicates with DL supervisory PLC over HS Profibus



Exciter System Drive PLC RoleExciter System Drive PLC Role

•

Drive PLC & 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



Drive PLC Example Functionality -

Details Showing Drive PLC & Supervisory PLC Split

Drive PLC Example Functionality -

Details Showing Drive PLC & Supervisory PLC Split

EXAMPLE PAGE 1 OF

APPROXIMATELY FOUR



Exciter ConfigurationExciter Configuration•

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 PLC



Exciter Performance TestingExciter 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



PLC Driven HMI Maintenance / Setup ScreensPLC Driven HMI Maintenance / Setup Screens

Range from Simple to Elaborate



CommunicationCommunication•

Drive PLC to exciters and to Supervisory PLC via HS Profibus

•

Gen exciter field commands to motor exciters via CAN protocol bus.

•

Supervisory PLC sends commands & reads data plus drive status in real time to mapped data area.

•

Data configuration is flexible



Circuit & Component DetailsCircuit & Component Details



DC ConvertersDC Converters•

Three-phase, up to 600 VAC in

•

Up to 600 volts DC out•

Two Basic Frames 120, 350 amp frames for 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.



Chopper Exciters Chopper Exciters •

Two Basic Frames: 150 & 300 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” & timed replacement or failures

DC

From S

ource

[-] VDC

6 W x 20 H

X 12 D

150 A



Compact ModulesCompact Modules

150 AExciter

300 AExciter

350 AConverter

Crowbar

9 H x 6 Wx 6 D



Output dv/dt Filter Output dv/dt Filter Simple dv/dt filter limits peak voltage output to motor and generator fields to equal or less

than 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]



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 [>900 v] or by drop out of fail-safe relay.



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

System Testing –

3 StagesDC-EXX

System Testing –

3 Stages

•

Initial testing –

2 Quadrant MG set 10 –

20 HP -

•

Follow-up dynamic testing –

PLC controlled, Full 4 Quadrant MG set 20 –

30 HP

•

High power testing on dynamic load with full control system May 2007



High Power Setup DataHigh Power Setup Data•

Gen field

40 henries, time constant >2.0 secondsField [cold] drop of ~300 volts DC.

•

Motor field 35.1 henries, time constant >2.0 sec secondsField [cold] drop of ~300 volts DC.

•

Both fields excited from 600 volt DC exciter bus.



Test Setup –

Test Floor EquipmentTest Setup –

Test Floor Equipment

A

B C

DE

FG

HPATCH PANEL



Test Setup –

Test InterconnectionsTest Setup –

Test Interconnections

752 load motor

2000 HP eddy curr dyno

MOTOR450 hp230 v

AC Motor Gen

shunt

excexc

Loadgrid

460 v3-ph

RECTIF GFEX

MFEX

CFB

1200 A

VFB

D

E

F

G H

DC-EXX PANEL A

C B



Test EquipmentTest Equipment

Eddy Current Load Dyno

Eddy Current Load Dyno

Traction Motor DC Load Machine

Traction Motor DC Load Machine

DC Driven Motor

DC Driven Motor

DC Driven Motor

DC Driven Motor

DC Main Generator

DC Main Generator

AC MG Drive Motor

AC MG Drive Motor



DC-EXX

Test EquipmentDC-EXX

Test Equipment

EXCITERS AND DRIVE PLC

MG SET WITH DC GEN AND AC DRIVE MOTOR

DC DRIVE MOTOR, EDDY CURRENT DYNO& DC LOAD MACHINE



Detailed Test ResultsDetailed Test Results



Armature Tapered Volt-Amp LimitsArmature Tapered Volt-Amp Limits

4 Quadrant Volt Amp Limits Regulator step..

VO

LTS

AMPS



Armature Tapered Speed-Amp LimitsArmature Tapered Speed-Amp Limits

4 Quadrant Speed Amp Limits Regulator step..

SP

EE

D

AMPS



Test: 0 to +/-100% Reference Step (250V) High inertia load

Test: 0 to +/-100% Reference Step (250V) High inertia load

Arm Amps

Arm Volts



Test: CEMF Running –

2.5s linear S-curve ramp, +250V to -248V

Test: CEMF Running –

2.5s linear S-curve ramp, +250V to -248V

Arm Amps

Arm Volts

RPM

Field Amps



Test: Traction motor torque steps –

Into Current limit with large load

NO OVERSHOOT!

Speed Amp Trace & Volt Amp Traces shown for reference

SPEEDAMP

VOLTAMP

VO

LTS

AMPS



Test: Traction motor torque steps –

Start at 150A at weak field & slam into current limit

STILL NO OVERSHOOT!

Speed Amp Trace & Volt Amp Traces shown for reference

SPEEDAMP

VOLTAMP

VO

LTS

AMPS



High-Power DC-EXX

Test Goals & ResultsHigh-Power DC-EXX

Test Goals & Results

Bottom line: High confidence in moving to actual excavator installation

Test Goal Result

1 Check dv/dt filter � Results approved for application to standard fields

2 Step Motor field current regulator for 30 – 40 Radians

Achieved 45 plus and could have pushed more

3 Step armature current regulator for 100 radians Achieved 110, with use of derivative function

4 Step Calculated speed regulator for 5 rad [no tach]

Achieved 6, and accurate enough to eliminate need for tach

5 Step voltage regulator for 10 rad without tach Achieved 13 rad without tach.

6 Current limit function in drive Works as specified.

7 Test current limit function from PLC Worked well.

8 Step CEMF regulator for 10 rad Achieved 16 rad & could have been more [added PID function to achieve this]

9 Check generator field over current protection “Actual test” proved function works.

10 Check motor field over current protection Proven.�

11 Test Rx3i PLC communications and outer loop functions

Tested functionality of TMGE blockware, & Profibus outer loop control



Ruggedizing –

Excavator VibrationRuggedizing –

Excavator Vibration•

Excavator vibration data gathered from mining shovels in hardrock mining were used as benchmark levels

•

Modules attached to test platforms, shaken to find natural resonances.

•

Endurance tests used to sort out areas needing attention.

•

Design changes made to modules and tests repeated for verification

DC-EXX 300 A ExciterOn Vibration Stand



Let’s ReviewLet’s Review



IGBT Common-Bus System Features-Benefits -

1IGBT Common-Bus System Features-Benefits -

1

1 Common Bus – allows field power sharing between motions

Smaller feed transformers & lower cost. .

2 Complete regulation & control during LE [Excitation] stop

Faster motion stop while protecting motors and generators

3 Fewer Excitation Transformers Less space, simpler, lower cost MCC and AC feeds

4 Low Harmonics and high power factor of diode vs thyristor converters.

Less heating & possible interference, smaller aux transf.

5 IGBT Power Switches vs Thyristors� Faster response, no cell state sensors, fewer devices

6Drive-level PLC sets excavator limits, formats communication, selects operating modes.

Simplified Supervisory PLC system and fast real-time monitoring .

7Smooth integration with machine supervisory controls and monitor systems.

Improved operating, maintenance and troubleshooting.

FEATURE BENEFIT



FEATURE BENEFIT

Bottom Line: IGBT field supplies offer unique advantages in MG set & exciter application.

8 Replace DC contactors used in field circuits with Thyristor

More reliable operation with same field circuit protection & braking.

9 Lower total system cost Better value.

10 Common Electronics Card set between all drives Fewer, common spares..

11 Smaller footprint of Base Drive on amp/amp basis

Better & smaller panel layout & maintenance

12 Simpler drive internal controls Easier troubleshooting & setup.

13 PLC master carries most motion protection and drive settings

Visible functionality for easier monitoring and maintenance�

14 Current but proven technology Long product life

IGBT Common-Bus System Features-Benefits -

2IGBT Common-Bus System Features-Benefits -

2



Present ActivityPresent Activity

•

Two upgrades being installed – March –

May Startup

•

New GE MG set draglines worldwide will use DC-EXX

•

Many upgrade inquiries in hand



Summary –

DC-EXX Excavator MG Control System

Summary –

DC-EXX Excavator MG Control System

•

Proven technology with real advantages for MG control

•

Cost, energy, maintenance, and space effective.

•

Easily integrated into a variety of onboard configurations.



Thanks!Thanks!

Office Location:

TM GE Automation Systems, LLC1501 Roanoke Blvd. [Office]2060 Cook Drive [Mailing]

Salem VA, 24153 USATEL: +1-540-387-5741; FAX: +1-540-387-7060

www.tmeicge.com

new dc-exx shared bus igbt mg control; bill horvath, tmgs - nov 07

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