rectifiers and controllers – update on the latest! symposium... · rectifiers and controllers –...
TRANSCRIPT
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Event: IHAA – Bi-annual conference
Date: 2018/09/2018
Place: Seattle, WA, USA Presented by: Frank Munk
Rectifiers and Controllers –
Update on the Latest!
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Why this presentation?
1. When it comes to new technologies I am often asking myself:
- Never heard about it – Did I miss something?
- What it this new technology about?
- Is this new technology suitable for my application?
- Industrial environment
- Robustness
- Services
2. What could be our benefit?
- Will we save on operation cost (Energy, Maintenance)?
- Will we become more productive?
- How can we make use of this new technology in the company?
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Drivers of developments
1. Making available
- Inventions lead to new products which make new applications available and
spin off to other industries
2. Making it more robust
- A new product needs to be reliable to keep operating costs low
3. Improving function
- Getting control to adjust it to the dynamics of the application
4. Improving performance
- Increasing power density to lower costs
5. Searching for new solutions to improve 2, 3, or 4 or changing needs
- Exploring new ideas to adapt to changing demands
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One of the first DC power sources using the
Dynamo principle Making available
Source: Frank Munk – Edison summer estate Fort Myers, Florida
Driver: We need light
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Ward - Leonard – converter
First controllable DC power source
Converter: Left hand side DC generator, right hand side three phase motor
Source: https://de.wikipedia.org/wiki/Umformer#/media/File:Rotierender_Umformer.jpg
Improving function
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Improving performance and function
1. Tube based rectifiers – Power conversion by electronics instead of a mechanical system
2. Solid state or diode rectifiers – Semiconductor material for conversion instead of tubes
Tap switch, reactors or Variac transformer for control
3. Thyristors or SCR (silicon controlled rectifier) – Semiconductor for conversion and control
Improving the performance of rectifiers by introducing new more powerful components to
reduce the number of components.
Combing functions to reduce the number of components
Increasing power by using liquid cooling at the component instead of an indirect air or oil
cooling around the component
Source: Google – Photos Tubes, Solid state, SCR
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Reducing size and weight by using a
Switch Mode Power Supply design to convert
AC into DC power
Driving factors which sparked the development of a new power
conversion technology years ago:
- Better process control by controlling process conditions for each part
instead of a bulk of parts (Reactor design instead of tank design)
- Less space to include a new line into the same building
- Less weight to ease installation work and reduce installation cost
- Predictive maintenance to reduce or avoid non-productive time (Interface)
- Reducing operation cost by reducing energy cost and improving efficiency
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Is the SMPS design ready for my application?
We opened up a SMPS design and manufacturing center almost 30 years ago. We have been
supplying SMPS rectifiers since then to various industries, in particular the plating industry.
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Trafo
SCR - Thyristor
Output: DC current
(Option) Ripple filter
Input: 3 x 380 - 480 V/ 50 – 60 Hz Primary Secondary
AC DC
Source: https://www.sunpower-uk.com/glossary/what-is-switch-mode-power-supply/
Design comparison – Traditional versus SMPS
SMPS
design
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Solid state rectifier – Variac control
Coolin
gofcom
ponets
Solid state rectifier – SCR control
Coolin
gofcom
ponents
SMPS – IGBT based
Co
olin
go
fco
mp
on
en
ts
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Co
ol
in
go
fc
om
po
ne
nt
s
Function block diagram - SMPS
Water or air
cooling
Note:
For all rectifier suppliers the backbone of
the SMPS, also called IGBT technology,
is a single power module which is put in
parallel or series to get to the required
output power
Air cooling
SMPS - Modular design to get more power
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Better process control by controlling process condition for each part instead of a bulk of parts
(Reactor design instead of tank design) – Modules are placed in one cabinet
Solutions now achievable by SMPS
6 x 25 V/1000 A in one cabinet – individual controlled and independent from each other
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Less space required to include a new line into the same building –
Less than ¼ of the volume and less than ½ of the foot print
Solutions now achievable by SMPS
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Less weight to ease installation work and reduce installation cost –
Less than 1 /3 of the weight – 25 V/ 4000 - > 5000 A
Solutions now achievable by SMPS
Power upgrade became an option now
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Components required for a traditional
1,000 – 10,000 A rectifier
Components needed for an SMPS – IGBT
based rectifier module 500 – 1500 A
rectifier module
Where there is light there is shadow - Complexity
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Electronic components also follow a life cycle and don‘t last forever
Conclusion:
The risk of a failure is increased for SMPS versus traditional rectifiers because
more components and power modules are needed to achieve the same power.
Life cycle graph of an electronic component
Early failure during
burn in or testing
Sudden failure
which happens
randomly
End of life:
Failures
happen more
regular
Time
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System reliability –Productivity, operation cost are influenced by the number of modules
Conclusion:
The risk of failure is increased by the power of n, n being the number of modules
n: Number
of modules
average component reliability R
Syste
m r
elia
bili
ty R
S
Presumption: System consist of n elements of the same,
with the same reliability Ri = R -> RS = Rn
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SMPS - higher efficiency
Energy cost saving makes your ROI –
Are you sure?
Efficiency graph shown in a rectifier
leaflet of an SMPS supplier
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SMPS and SCR can both offer a high efficiency
The SCR design makes the difference
Same efficiency graph updated by us
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SMPS and SCR efficiency is ranging between
80 - 90 % for anodizing rectifiers already
Graph updated by us
30 %
80 %
Don’t get mislead by a graph
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Summary
Yes SMPS rectifiers offer new alternative ways to improve your
process productivity but space and energy cost saving might not help
you to reduce your operation cost
Achtung!New school:
Multiple modules together to get to the same
output power level of a traditional rectifier.
Old school:
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Trends in control systems
1. PLC system on process level become more and more affordable
- Complex algorithm can be stored in the controller
- IoT ready interface on board
2. Touch panel systems became more robust and can now simplify operation
- Mobile phone generation has different needs
3. Enter your “destination”, the goal you like to achieve, and let the controller do the job
to give you extra time for other work
4. Know what you did to find the root cause of a problem if needed
5. Interface with the IT world of your company – Make process information available
- IoT also means that data become more easily available
- Big data analysis algorithm allow you to do better next time
6. Online information and remote access for a better service
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Dedicated process controllers are used in manual
lines or integrated into fully automated lines
Making process data available and
using expert know how in automated
lines
Increase productivity, improve
quality in manual lines
--
Expert know how is made available
for other tasks in production
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4th generation of process controllers for
aluminum anodizing and coloring applications
1. More versatility to be able to do more than just one alloy
2. More process information to allow online-monitoring (trend lines)
3. Simplifying complex programming to design a treatment program
to the alloy needs
4. Remote monitoring, remote access offering IoT ready interfaces
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Touch panel display simplifies operation
1st step:
Select a mode:
Manual or automatic
(complex program)2nd step:
Select a program using the
program library 3rd step:
Start and monitor the process
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Know what you are doing or what happen –
A graph can help
Process overview
Program overview
What happen?
“Online”-screen – Live
data and history data
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Industry 4.0 / Internet of Things
Smart network on process level
Office IT
networkRemote access
manager
Operational Technology (OT) network
Process level networkHardware and software which changes the physical
process through direct monitoring and/or control of
physical devices such as pumps and rectifiers
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IT and OT start to collaborate
The new process controller should be IoT ready which
means that they can be integrated into an OT network
structure to make process data and system status
information data available to other levels in the network and
the company
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Summary
• SMPS rectifiers are not new to the industry they are available for
about 30 years but due to the given capacity they are commonly
just in the plating industry
• Energy efficiency was not the driver for the SMPS development. It
was space and control of rather a part than a batch which drove the
development.
• Traditional rectifier designs can reach efficiency levels of 80 – 90 %
as well
• SMPS have an excellent power factor but create high harmonics and
can trigger oscillations in the factory due to the none linear load
current – Watch out for impedance limits by the rectifier supplier
• SMPS have side effects (Lifetime, System reliability, Harmonics)
• New process controllers can do complex recipes and become
easier to handle
• IT and OT world start to collaborate to improve the productivity
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Congratulations
- You made it!
If you have any questions or
comments please approach us
[email protected] - www.rectifier.com