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Title: VARIABLE SPEED OF 6RA70 DC DRIVE FOR

Description:

In industrial applications, machine tools make use of motors for axis feeds and spindle rotation applications. Generally, DC motors are used for this purpose. The speed of these motors is controlled in conventional methods i.e. Ward-Leonard system, multiple voltage control method, rheostatic control method etc. However, these methods are analog in nature and are obsolete now which offer a number of limitations like less reliability, less stability, less maintainability, poor system response etc. These limitations result in more cycle time of production and less productivity. These can be overcome by replacing the conventional methods with microprocessor controlled digital DC Drives. This project gives such an application for DC motor speed control (for axis feed and spindle rotation) on many of the machines at BHEL, Hyderabad. Some of the advantages for using such drives for various purposes are discussed at the end of the project.

INTRODUCTION

DC motors have a wide range of applications in day-to-day life. They are widely used in applications requiring adjustable speed, good speed regulation and frequent starting, braking and reversing. Some of the important applications of DC motors are rolling mills, paper mills, mine winders, hoists, machine tools, traction, printing presses, textile mills, excavators and cranes. Although AC motors are expensive than DC motors, they are used in number of applications such as fans, blowers, mill run-out tables, cranes, conveyers, traction etc…because of their variable speed. But still AC motors are dominated by DC motors because of their excellent operational properties and control characteristics. The reliability and simple control of DC motors make them more popular. With the advancement of semiconductor technology AC drives could not immediately supplant DC drives.

DC Motor:

What is a DC motor?

• A DC motor is a DC machine which converts electrical energy into mechanical energy.

Methods of Armature Voltage Control:

Variable armature voltage for speed control, starting, braking and reversing of DC motors can be obtained by the following methods:

When the supply is AC

1) Ward-Leonard schemes.

2) Transformer with taps and an uncontrolled rectifier bridge.

3) Static Ward-Leonard scheme or controlled rectifiers.

When the supply is DC

1) Chopper control.

Let us discuss a few of the above methods in detail.

Ward-Leonard Drives: This method is known after the name of its inventor H. Ward Leonard. It consists of a separately excited generator feeding the DC motor to be controlled. The generator is driven at a constant speed by an AC motor connected to 50 Hz AC mains. The driving motor may be an induction or a synchronous motor. When the source of power is not electrical, generator is driven by a non-electrical prime mover such as diesel engine or gas turbine. While the DC motor may be driven at low speeds, resulting in high torque and relatively large frame size, generator being of the same voltage, current and power ratings as the motor can run at a higher speed with a view to reduce its cost and size.

Motor terminal voltage is controlled by adjusting the field current of the generator. When the field winding voltage is smoothly varied in either direction, the motor terminal voltage and therefore, speed can be sleeplessly varied from full positive to full negative.

One of the important features of this drive is the inherent ability for regenerative braking down to very low motor speeds. This combined with the variation of armature voltage in either direction allows efficient operation of drive in all four quadrants of speed-torque plane. For regenerative braking, the output voltage of generator G is reduced below the induced voltage of motor M by decreasing the generator field current. This reverses the current flowing through the armatures of G and M. Now machine M works as a generator and G as a motor. Mechanical energy provided to machine M, either from the kinetic energy of rotating parts or due to an

Parts of Electric Drives:

Electrical drive has following major parts: load, electrical motor, power modulator, control unit and source.

There are large numbers of loads and each load has its own specific requirements.

Electrical motors: Motors commonly used in electrical drives are: DC motors – shunt, series, compound and permanent magnet; Induction motors – squirrel cage, wound rotor and linear; Synchronous motors – wound field and permanent magnet; Brush less DC motor; Stepper motors; and Switched reluctance motors.

In the past, induction and synchronous motor were employed mainly in constant speed drives. Variable speed drives consisting these machines were either too expensive or had very poor efficiency. Consequently, variable speed drive applications were dominated by DC motors.

Power modulators: Power modulators can be classified as: Converters, Variable impedances and switching circuits.

Control unit:

A unit called control unit controls the power modulator. All the controls for power modulator are provided in this unit. The nature of control unit for a particular drive depends on the power modulator that is used. When semi conductor converters are used, the control unit will consist of firing circuits, which employ linear and digital integrated circuits and transistors, and a microprocessor when sophisticated control is required. When control of switching circuits is required for any purpose then the function of control unit will be to provide sequencing and interlocking. Solid state relays are used when control is complex and in such cases programmable logic controllers (PLC’s) can be used.

Speed – Torque Conventions and Multi quadrant Operation:

For consideration of multi quadrant operation of drives, it is useful to establish suitable conventions above the signs of torque and speed. Motor speed is considered positive when rotating in the forward direction. For drives which operate only in one direction, forward speed will be their normal speed. In loads involving up-and-down motions, the speed of motor which causes upward motion is considered forward motion. For reversible drives, forward speed is chosen arbitrarily. Then the rotation in opposite direction gives reverse speed which is assigned the negative sign. Positive motor torque is defined as the torque which produces acceleration or the positive rate of change of speed in forward direction. Positive load torque is opposite in direction to the positive motor torque. Motor torque is considered negative if it produces deceleration.

A motor operates in two modes – motoring and braking. In motoring, it converts electrical energy to mechanical energy, which supports its motion. In braking, it works as a generator converting mechanical energy to electrical energy, and thus, opposes the motion. Motor can provide motoring and braking operations for both forward and reverse directions.

Show below in the graph the torque and speed coordinates for both forward (positive) and reverse (negative) motions.

Line Synchronizing Circuit:

The main function of the synchronizing circuit is to derive low voltage signals to the control circuit which operates at low voltages. These low voltage signals must be synchronized to supply the voltages to the main power circuit. Step-down transformer may be used for this purpose with filter circuit to avoid waveform distortion, if any. While deriving the modulating voltages at the supply frequency the phase shifting network may also be required. To determine the instant at which the firing pulses are to be released to the thyristors in the two converter groups the modulating voltages are compared with the reference voltage.

Timer and Logic circuit:

In this circuit the reference voltage is compared with the modulating voltage. Comparator produces short pulses. These pulses drive clock pulse generator which is a positive edge triggered monostable multivibrator. Therefore we get six pulses. These short pulses act as clock pulses to the flip-flops. The clearing of pulses is done when not required. This limits the pulse presence only when that thyristor is supposed to conduct otherwise the pulse is blocked. The logic circuit reference signals and modulating signals could be of any wave shape. In most applications sinusoidal reference signals and co-sinusoidal modulating signals are commonly employed. The basic principle of the co-sinusoidal modulation is the same as that of cosine wave crossing pulse-timing control.

Pulse Amplifier:

The phase circuits in which the main circuit current paths include two thyristors in series such as the fully controlled bridge converter which require that each thyristor should receive two firing pulses in each cycle unless a single pulse of sufficient duration to embrace both firing constants. Deriving the pulse for each thyristor from two appropriate phases can do this.

INTRODUCTION TO SIMOREG DIGITAL DRIVE

The SIMOREG 6RA70 DC MASTER is known the world over for its outstanding quality, reliability and over all the performance. With features such as feed forward control on all of the inner control loops and a 83ns instruction time made possible by its powerful co-processor system the SIMOREG 6RA70 DC-Master stands unchallenged on its performance from every edge of the globe.

A major function of an adjustable speed DC controller is to provide closed-loop control of process variables. The 6RA70 drive provides closed-loop regulators for speed, motor armature current, CEMF voltage, and motor shunt field current.

Microprocessor controls are desirable because of their precision and repeatability.

However, a major drawback with many microprocessor controllers has been the slow response of their closed-loop controllers, relative to analog control. One of the features that sets our microprocessor control concept apart from all others is the use of “Feed Forward Control” inside control loops. Feed Forward essentially uses process modeling techniques to precondition regulator output, providing operational benefits:

• Control loop calculations are faster because the domain for mathematical convergence is smaller.

• Microprocessor is not slowed by long calculations.

Each of the closed-loop regulators in a drive controller must be tuned to the specific motor and load characteristics of the application. One of the outstanding features of the 6RA70 drive is the automatic tuning functions of various control loops, including current regulator, speed regulator, field current regulator, and CEMF regulator without additional equipment, high level technical experience, or trial and error adjustments. Calculations are made automatically by the drive during the tuning process and stored in the drives memory for constant reference. Simply enter parameters, press a few buttons and the drive does all the work.

The SIMOREG 6RA70 DC Master is extremely flexible and cost effective in any application. In to the ability to expand the standard functionality by adding option boards, the standard version can be expanded to handle high level software application with the built in extended technology software. In many applications the use of extended technology software can replace a technology board or even a PLC function.

The SIMOREG 6RA70 DC Master was designed as a truly integrated member of the SIEMENS MASTER DRIVES family. The 6RA70 having identical card rack and BICO software technology as the 6SE70 AC Drive lends itself to using the same option cards including Profibus CBP2 card, Simolink SLB card, T400 technology card etc., In addition to using the same option cards as the 6SE70 AC MASTERDRIVE series, addition devices such as the OP1S Operator Control Panel are also interchangeable. This concept can greatly reduce the inventory in addition to adding versatility and operator friendliness to drive systems.

In recent years majority of the drive controls have migrated from traditional hard wiring to serial communication. The SIMOREG 6RA70 DC Master series was designed with this migration in mind and is capable of fully integrated into any automation environment. The Technology Controller is a general PID controller that is built-into the 6RA70 is available for such functions as outer loop tension or dancer position control. The cabinet units include all of the components which are required to operate a variable speed DC motor.

SIMOREG 6RA70 converters are characterized by their compact, space-saving design. An electronics box containing the closed-loop control board is mounted in the converter door. This box also has space to hold additional boards for process related expansion functions and serial interfaces.

This design makes them especially easy to service since individual components are easily accessible. External signals (binary inputs/ outputs, analog inputs/outputs, pulse encoders, etc.) are connected by way of plug-in terminals. The converter software is stored in a flash EPROM. Software upgrades can easily be loaded via the serial interface of the basic unit.

For customer convenience and added versatility the SIMOREG 6RA70 DC-MASTER is available in the base drive and power module designs. The SIMOREG 6RA70 is available in high Hp designs up to 8,000Hp.These designs retain all the functionality and commonality of the standard SIMOREG 6RA70.One Of the many features of the SIMOREG 6RA70 DC-MASTER is the ability to parallel up to five identical power modules for increased power capabilities and redundancy. Through the use of the CUD2 terminal expansion card a paralleling interface is readily available to send the summated firing pulses to all connected units.

Design:

The cabinet units contain the following components:

• SIMOREG DC-MASTER 6RA70 drive converters with microprocessor-based digital closed-loop control for the armature- and field circuits

• Main switch (=D3-Q11)

• Main contactor (=D3-K11)

• Field contactor (=G1-K11)

• Circuit-breaker

• Motor protection circuit breaker

• Fuses

• Commutating reactors

• Matching transformers

• Display- and operator control elements

• Terminals

• Cooling.

The components are mounted in a cabinet, and are ready to be Connected up. All of the components are accessible from the front of the cabinet, i.e. the cabinet units can be mounted with their rear panels to walls. For units up to 60 A, the main switch is mounted on the side.

Line supply:

Cabinet units can be directly connected to three-phase line supplies (refer to Technical Data for the nominal data). The feeders cables to the drive converter must be protected against short-circuit and overload (DIN VDE 0160/ DIN VDE 0100, Part 540).

Main switch:

For cabinet units from 15 to 1200 A, the three-phase line supply is connected to the unit via the main switch =D3-Q11. Cabinet units larger than 1200 A have an electrically actuated circuit-breaker =D3-Q11 and a main switch =D3-S11.

Main contactor/Circuit-breaker:

The main contactor =D3-K11 or the circuit-breaker =D3-Q11 can be switched-in or -out using a relay, mounted in the cabinet unit via the field contactor =G1-K11. A microprocessor in the drive converter automatically controls the relay at the correct instant within the power-up or power-down routine.

Circuit-breaker and motor protection circuit-breaker:

Circuit-breaker and motor protection circuit-breaker protect the electronics power supply and the fan against short-circuit and overload.

Fuses:

SITOR or SILIZED fuse links and MCBs protect the thyristors and the field rectifier of the cabinet unit as well as the auxiliary circuits and the motor fan. The base drive panel designs consist of the power module mounted on a base panel with the addition of line fuses, control transformer, and contactor.

Commutating reactors:

Commutating reactors for the armature- and field circuit limit the commutating dips in the line supply voltage in accordance with DIN VDE 0160. They are rated for operation with 100 % rated DC current.

Matching transformers:

A matching transformer 400/230 V is used for the electronics power supply and the open loop control. For drive converter input voltages greater than 3-ph. 400 V AC, an additional adaptation transformer is also be included in the unit which steps down the incoming voltage to 400 V for the field circuit, the motor fan, and, for drive converters with rated currents above 400 A, also for the drive converter fan.

Display and operator control elements:

The following equipment is mounted in the cabinet doors

• EMERGENCY-OFF pushbutton (Emergency stop)

• 10-turn set point potentiometer

• Mode selector switch,

• INTERNAL-EXTERNAL

• OP1S operator control panel.

The operator control panel is used to

• Set the cabinet unit parameters

• Display measured values

• The open-loop control is executed in the INTERNAL mode:

– Set point input via motorized potentiometer

– Power-on (I)

– Power-down (O)

– Jogging

Cooling:

Converters with rated DC currents up to 100A are self cooled, while converters with rated DC currents of 140A and higher have forced-air cooling (fan assembly).

“External” operating mode:

In this mode, the set point is entered and the equipment controlled via the terminals of the unit. The field circuit is a half-controlled B6HZ single-phase bridge connection. For converters with 15 to 850A (1200 A at 400 V supply voltage) rated DC current, the power section for armature and field is constructed of isolated thyristor modules. The heat sink is thus potential free.

In addition to the options with codes, SIMOREG cabinet units can be equipped with additional options with drive converter transformers, devices for field supply, and different degrees of protection. External signals (binary inputs/ outputs, analog inputs/outputs, pulse encoders, etc.) are connected by way of plug-in terminals. The converter software is stored in a flash EPROM. Software upgrades can easily be loaded via the serial interface of the basic unit.

Converters for single-quadrant or four-quadrant operation are available to suit individual applications. As the converters feature an integrated parameterization panel, they are autonomous and do not require any additional parameterization equipment. All open-loop and closed-loop control tasks as well as monitoring and auxiliary functions are performed by a microprocessor system.

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Title: VARIABLE SPEED OF 6RA70 DC DRIVE FOR

download VARIABLE SPEED OF 6RA70 DC DRIVE FOR project

download VARIABLE SPEED OF 6RA70 DC DRIVE FOR project