AFE Drives for B.E. 495 Shovels
Transcript of 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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