AFE IGBT AC Drives For Bucyrus

495BII Shovels
The Western Mining Electrical
Association
Albuquerque, New Mexico
November 16, 2000
Frank G. Wickert
Bucyrus International, Inc.
BUCYRUS INTERNATIONAL
GE STATIC DC DOM+ ( 301M 204M )
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
BUCYRUS INTERNATIONAL
ACUTROL SERIES III
INSULATED GATE BIPOLAR
TRANSISTORS (IGBT)
FUSELESS, SNUBBERLESS INVERTERS
ACTIVE FRONT END
INTEGRAL DIAGNOSTIC COMPUTER
BUCYRUS ACUTROL III IGBT
DISTRIBUTION SYSTEM COMPATIBILITY
MAINTAINABILITY
SUPERIOR PERFORMANCE
AFE
Active Front End
Replaces traditional
forward/regenerative
rectifier
Same hardware as
inverter
IGBT based
Modular design
Lower harmonics
Leading PF capability
495BII Shovel
Propel 1
Cap.
Overvoltage
protection
PWM Inverters
Motions
Swing
500 HP
Crowd
700 HP
700 HP
2240 HP
Swing
500 HP Swing
Hoist
1400 V
1400 V
1400 V
1400 V
1400 V
1400 V
Precharge circuit
R
p
PT
PT
PT
L reactor
R
p
R
d
R
g
R
g
R
g
R
g
Propel 2
700 HP
1400 V
XFO 1
Ground
detection circuit
Discharge
resistor
Voltage
sensor
XFO 2
Short-
circuit
diode
C
b
D
1
C
g
AFE
L reactor
L reactor
L reactor
7200 Volts - 60 Hz
6600 Volts - 50 Hz
480 Volts - 60 Hz
380 Volts - 50 Hz
Acutrol III (IGBT)
IGBT Active Front End Block
Diagram
VSS
SIBAS Control
Precharge
Input Contactor / CB Input Reactor
AFE DC Bus Cap. Inverter
AC
Motor
AFE Stagger
Pulse pattern = 15
Pulse frequency = 15 (60) = 900 Hz
Stagger = 360(fund.)/{(pulse f)(# AFEs)]
Stagger = 360(60)/[(900)(4)] = 6 degrees
AFE IGBT Firing
Triangular modulation signals @ 900 Hz
Sine wave reference signal
Comparative circuit used for switching
DC bus & PF regulator adjust amplitude of
reference to set actual points of firing
AFE Stagger
-1.5
-1
-0.5
0
0.5
1
1.5
0 50 100 150 200 250 300 350 400
degrees
sinwt
afe1
afe2
afe3
afe4
AFE Stagger
-1.5
-1
-0.5
0
0.5
1
1.5
0 10 20 30 40 50 60
degrees
sinwt
afe1
afe2
afe3
afe4
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
-1.5
-1.0
-0.5
0.0
0.5
1.0
1.5
-1.5 -1.0 -0.5 0.0 0.5 1.0 1.5
Regenerative Watts - Motoring Watts (pu)
L
a
g
g
i
n
g

V
a
r
s

-

L
e
a
d
i
n
g

V
a
r
s

(
p
u
)
A - 81% Line Voltage
B - 90% Line Voltage
C - 100% Line Voltage
D - 110% Line Voltage
E - 0.9 Leading PF
A
B
C
D
E
E
F
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
H
a
r
m
o
n
i
c

O
r
d
e
r


h
Harmonic Current [ % ]
0
.
0
0
%
0
.
0
5
%
0
.
1
0
%
0
.
1
5
%
0
.
2
0
%
0
.
2
5
%
0
.
3
0
%
0
.
3
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
H
a
r
m
o
n
i
c

O
r
d
e
r


h
Harmonic Current [ % ]
IGBT has fast
reaction to
changes in
current.
Eliminates all
fuses.
Active Front
End
Operates at a Unity
Power Factor and
<5% total harmonic
distortion.
Siemens
unitized welded
electrical skid
cabinet.
Increased
rigidity and
strength.
Enhanced
diagnostic
computer with
multi-language
capability.
Acutrol III (IGBT)
AC Drive
System
Benefits
495BII Shovel
Simple, routine
maintenance.
No brush or
comutator
maintenance.
No flashover.
Fewer internal
connections.
Shorter rewind
lead time.
Lower rewind
costs.
Acutrol III (IGBT)
Benefits
AC- IGBT
Benefits over
DC Drive
495BII Shovel
AC Drive
System
No UPS
(Uninterrupted
Power Supply).
Safe shutdown on
power loss is
inherent.
PLC in drive
control.
Eliminates the
PLC cabinet.
Remote start
panel in
operators cab.
Control and logic
signals are sent
to PLC via remote
I/O. (operators
controls, encoders,
MCC, Lube Drive
Motor temperature
and brake
monitoring)
Acutrol III (IGBT)
Benefits
495BII Shovel
MAINTAINABILITY
RUGGED AC MOTOR
IMPROVED TACHGENERATOR
IMPROVED SKID CONSTRUCTION
UPS ELIMINATED
REGEN RESISTOR ELIMINATED
GREATER MTBF
MOTOR MAINTAINABILITY
NO BRUSHES OR
COMMUTATORS
IMPROVED DIGITAL
SHAFT MOUNTED
SPEED SENSORS
ARMORED CABLE TO
MINIMIZE COMMON
MODE NOISE AND
GROUND CURRENT
Maximized Reliability
Speed Sensor
Evolution
Spieth element or
clamp for mounting on
shaft.
Spieth element
Acutrol II (GTO) & Acutrol III (IGBT)
Sealed bearings and
labyrinth shaft seal.
720 pulses per
revolution instead of
1024.
Clean disk with
compressed air.
Replaceable electronic
module.
Maximized Reliability
Cabinets bolted
and welded on a
common skid.
Acutrol II (GTO)
Wire harness.
Tested as a
complete unit.
Digital controls
without temp. drift
requires no
tune-up.
Dust-proof control
cabinet.
Maximized Reliability
Single welded
Enclosure
Acutrol III (IGBT)
Separation of clean
and dirty air
Wire harness.
Tested as a
complete unit.
Digital controls
without temp. drift
requires no
tune-up.
Dust-proof control
cabinet.
SYSTEM MAINTAINABILITY
DRIFT FREE DIGITAL
ACUTROL CONTROL
RUGGED WELDED
ELECTRICAL SKID WITH
CLEAN AND DIRTY AIR
ISOLATION
REMOTE PLC I/O FOR
FEWER CONNECTIONS
POWER ELECTRONICS
IGBT FOR INVERTER AND AFE
PROTECTION IS ACHIEVED WITHOUT
FUSES OR SNUBBER CIRCUITS
GATE DRIVERS ARE LOW POWER
COMPARED TO SCRS AND GTOS
FEWER COMPONENTS MEANS
IMPROVED RELIABILITY
IGBT MODULE
IGBT: 3300 V, 1200 Amp
Motor Voltage : 1400 V
Acutrol III (IGBT)
Maximized Reliability
IGBT's (Insulated Gate Bipolar Transistor)
used as power switches.
No snubber circuits or fuses required.
Transitor needs only low power gating
signal to turn on and off.
Same IGBT power modules for Active
Front End (AFE) and inverter with "plug-
in" design.
INSIDE AN IGBT MODULE
COMPATIBILITY
ACTIVE FRONT END ( AFE )
FULL REGENERATION
UNITY POWER FACTOR
LESS THAN 5% TOTAL HARMONIC
DISTORTION
PLUS 10% MINUS 20% INPUT VOLTAGE
Distribution System Compatibility
Acutrol III (IGBT)
Power Factor 1.0 .8 lead - .8 lag
Input Voltage +10% +10%
-20% -20%
THD 11% <5%
RPC YES NO
DC Static AC-IGBT (w/AFE)
CONTROL ELECTRONICS
ACUTROL III DIGITAL CONTROL FOR
BOTH INVERTER AND AFE
PROVEN LOW SPEED CONTROL
STRATEGY
MIL SPEC COMPONENTS FOR LOW
TEMPERATURE APPLICATION
PARAMETER SELECTABLE MACHINE
ADJUSTMENTS
CONTROL CONCEPT
CONTROL ELECTRONICS
OVERCURRENT TRIPS MINIMIZED BY
RIDE THROUGH ABILITY
PLC, ACUTROL III CONTROL,
DIAGNOSTIC COMPUTER,
COMMUNICATION VIA PROFIBUS
DIAGNOSTIC COMPUTER
INTEGRAL WITH ACUTROL III CONTROL
AND MACHINE PLC
SIMPLIFIED GRAPHICAL INTERFACE
FOR RAPID PROBLEM DETECTION
TOUCH SCREEN FOR EASY NAVIGATION
BUILT IN TROUBLESHOOTING MANUAL
DIAGNOSTIC COMPUTER
DIAGNOSTIC COMPUTER
DIAGNOSTIC COMPUTER
DIAGNOSTIC COMPUTER
REMOTE DIAGNOSTICS
IGBT SUMMARY
PRODUCTIVITY ADVANTAGES OF
SERIES I AND II MAINTAINED
NO ROUTINE MAINTENANCE WITH AC
MOTORS
IMPROVED TACH RELIABILITY
IMPROVED DIAGNOSTICS
BEST COMPATIBILITY OF ANY STATIC
DRIVE
From Past Successes
to Future Innovations
Hydraulic Crowd
Benefits
Reduced Impact
Loading
No Crowd Rope or Rack
& Pinion Maintenance
Ease of Maintenance
Environmentally
Friendly
795B
795B
Power Unit
Located on
Machinery Deck
Eliminated
traditional
Crowd
Machinery
No Handle or Rack Lube
Required
795-B DECK PLAN
Electrical
AC - IGBT (Insulated Gate Bipolar Transistor)
Electrical Control
Room
Rugged Skid
Structure
Fuseless Drive
Swing & Hoist motors are
interchangeable with 495B
No Uninterrupted
Power Supply (UPS)
Regenerates to Line
Diagnostic
Computer
Standard 3Ph/60Hz/7200v
Option to 15,000v
Rapid reaction time
Carry-over capability
through electronics
Additional power
regulated through a
United Power System
Consolidation of
components
Reduced vibration input
495B with upgrades
Soft-Dump
Latchless Dipper
Benefits
Unique Design
Patent Applied For
Improved MTBF and
MTTR
2-Pass Load 240 Ton
Haul Trucks
Reduced Truck and
Operator Impact
No Latch Lever No
Latch Bar
No Latch Keeper No
Trip Rope
12 Dia. Cylinder
Metered Dump
Optimized Hinge
Location
Provides an Additional
2.5 Feet of Dumping
Height
C
L
Bucyrus
Loading
Advantage
422 Min
(12.85m)
(Tail Swing = 39)
592 Max
(18.03m)
CAT 797 CAT 797
17 window for
haul truck positioning.
Large positioning
window for reduced
haul truck spotting
times.
Existing shovel
designs require
alignment under
boom point.
Moving Into The Next Generation
0
20
40
60
80
100
F
e
e
t
195B 295B 495B 595B 795B 795B 795B 795B
THE NEXT THE NEXT THE NEXT THE NEXT
GENERATION GENERATION GENERATION GENERATION
395B