afe drives for b.e. 495 shovels

8/13/2019 AFE Drives for B.E. 495 Shovels

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AFE IGBT AC Drives For B

495BII ShovelsThe Western Mining Electric

Association

Albuquerque, New MexicoNovember 16, 2000

Frank G. Wickert

Bucyrus International, Inc.


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BUCYRUS INTERNATIO GE STATIC DC DOM+ ( 301M 204

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


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BUCYRUS ACUTROL III DISTRIBUTION SYSTEM COMPA

MAINTAINABILITY

SUPERIOR PERFORMANCE


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AFE Active Front End

Replaces traditional

forward/regenerative

rectifier

Same hardware as

inverter

IGBT based

Modular des

Lower harm Leading PF


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495BII Sho

Cap.

Overvoltage

protection

PWM Inv

Precharge circuit

Rp

PT

PTPT

L reactor

Rp

Rd

Rg

Rg

Rg

Rg

XFO 1Ground

detection circuit

Discharge

resistor

Voltage

sensor

XFO 2

Short-

circuitdiode

Cb

D1

Cg

AFE

L reactor

L reactor

L reactor

7200 Volts - 60 Hz

6600 Volts - 50 Hz

480 Volts - 60 Hz380 Volts - 50 Hz

Acutrol III (IGB


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IGBT Active Front End

Diagram

VSS SIBAS Control

Precharge

Input Contactor / CB Input Reactor

AFE DC Bus Cap.


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AFE Stagger Pulse pattern = 15

Pulse frequency = 15 (60) = 900 Hz

Stagger = 360(fund.)/{(pulse f)(# AF

Stagger = 360(60)/[(900)(4)] = 6 deg


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AFE IGBT Firing Triangular modulation signals @ 900

Sine wave reference signal

Comparative circuit used for switchin

DC bus & PF regulator adjust amplitu

reference to set actual points of firing


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AFE Stagger

-1.5

-1

-0.5

0

0.5

1

1.5

0 50 100 150 200 250 300

degrees


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AFE Stagger

-1.5

-1

-0.5

0

0.5

1

1.5

0 10 20 30 40

degrees


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AC source

voltage

AFE

reactor

AFE AC input

voltage

I Vsource

Vreactor

Vafe

Vreactor

Vsource

Vafe

I

Vsource

Vreactor

Vafe

I

PF=1

PF leading

PF lagging


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-1.5

-1.0

-0.5

0.0

0.5

1.0

1.5

-1.5 -1.0 -0.5 0.0 0.5

Regenerative Watts - Motoring Watts (p

LaggingVars-LeadingVars(pu

)

A- 81% Line Voltage

B- 90% Line Voltage

C- 100% Line Voltage

D- 110% Line Voltage

E- 0.9 Leadin PF

E


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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

HarmonicOrderh

Harmonic Current [ % ]


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0.00%

0.05%

0.10%

0.15%

0.20%

0.25%

0.30%

0.35%

06

12

18

24

30

36

42

48

54

60

66

72

78

84

90

96

102

108

114

120126

132

138

144

HarmonicOrd

erh

Harmonic Current [ % ]


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IGBT has fast

reaction to

changes in

current.

Active Front

End

Siemens

unitized welde

electrical skid

cabinet.

Acutrol III (IGB

AC DriveSystem

495BII Sh


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Acutrol III (IGB

AC- IGBTBenefits over

DC Drive

495BII Sh


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MAINTAINABILITY RUGGED AC MOTOR

IMPROVED TACHGENERATOR

IMPROVED SKID CONSTRUCTIO

UPS ELIMINATED

REGEN RESISTOR ELIMINATED

GREATER MTBF


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MOTOR MAINTAINABI NO BRUSHES ORCOMMUTATORS

IMPROVED DIGITAL

SHAFT MOUNTEDSPEED SENSORS

ARMORED CABLE TO

MINIMIZE COMMON

MODE NOISE AND

GROUND CURRENT


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Maximized Re

Cabinets boltedand welded on acommon skid.

Acutrol II (GT

Wire harness.

Tested as acomplete unit.

Digital controls

without temp. drift

requires no

tune-up.

Dust-proof control

cabinet.


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Maximized Re

Single weldedEnclosure

Acutrol III (IGB

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.


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SYSTEM MAINTAINAB DRIFT FREE DIGITAL

ACUTROL CONTROL

RUGGED WELDED

ELECTRICAL SKID WITH

CLEAN AND DIRTY AIRISOLATION

REMOTE PLC I/O FOR

FEWER CONNECTIONS


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POWER ELECTRONI IGBT FOR INVERTER AND AFE

PROTECTION IS ACHIEVED WIT

FUSES OR SNUBBER CIRCUITS GATE DRIVERS ARE LOW POWE

COMPARED TO SCRS AND GTO

FEWER COMPONENTS MEANS

IMPROVED RELIABILITY


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IGBT MODULE


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IGBT: 3300 V, 1200 Amp

Motor Voltage : 1400 V

Acutrol III (IGBMaximized Re

IGBT's (Insulated Gate Bi

used as power switches

No snubber circuits or f

Transitor needs only lowsignal to turn on and off

Same IGBT power modu

Front End (AFE) and inv

in" design.


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INSIDE AN IGBT MOD


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Distribution System CompaAcutrol III (IG

Power Factor 1.0 .8 lead -

Input Voltage +10% +10-20% -20

THD 11%


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CONTROL ELECTRON ACUTROL III DIGITAL CONTRO

BOTH INVERTER AND AFE

PROVEN LOW SPEED CONTROLSTRATEGY

MIL SPEC COMPONENTS FOR LO

TEMPERATURE APPLICATION

PARAMETER SELECTABLE MAC

ADJUSTMENTS


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CONTROL CONCEP


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CONTROL ELECTRON OVERCURRENT TRIPS MINIMIZE

RIDE THROUGH ABILITY

PLC, ACUTROL III CONTROL,DIAGNOSTIC COMPUTER,

COMMUNICATION VIA PROFIBU


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DIAGNOSTIC COMPU INTEGRAL WITH ACUTROL III C

AND MACHINE PLC

SIMPLIFIED GRAPHICAL INTERFOR RAPID PROBLEM DETECTIO

TOUCH SCREEN FOR EASY NAV

BUILT IN TROUBLESHOOTING M


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DIAGNOSTIC COMPU


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DIAGNOSTIC COMPU


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DIAGNOSTIC COMPU


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DIAGNOSTIC COMPU


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REMOTE DIAGNOSTI


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IGBT SUMMARY PRODUCTIVITY ADVANTAGES O

SERIES I AND II MAINTAINED

NO ROUTINE MAINTENANCE WMOTORS

IMPROVED TACH RELIABILITY

IMPROVED DIAGNOSTICS

BEST COMPATIBILITY OF ANY S

DRIVE


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Hydraulic Crowd

795B795B

Power UnitLocated on

Machinery Deck

Eliminated

traditional

Crowd

Machinery

No Handle or Rack Lub

Required


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ElectricalAC - IGBT (Insulated Gate Bipolar Transistor)

Electrical Control

Room

Rugged Skid

Structure

Fuseless Drive

Swing & Hoist motors are

interchangeable with 495B

No UninterruptedPower Supply (UPS)

Regenerates to Line

DiagnosticComputer


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Soft-Dump

Latchless Dipper

Unique DesignPatent Applied For

No Latch Lever No

Latch BarNo Latch Keeper No

Trip Rope

12 Dia. Cylinder

Metered Dump

Optimized Hinge

Location


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CL

Bucyr

Loadin

Advant

422 Min

(12.85m)

(Tail Swing = 39)

592 Max

(18.03m)

CAT 797CAT 797

17 window forhaul truck positioning.


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Moving Into The Next Gen

0

20

40

60

80

100

195B 295B 495B 595B395B


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afe drives for b.e. 495 shovels

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