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 HPSwing

Hoist

1400 V

1400 V

1400 V

1400 V

1400 V

1400 V

Precharge circuit

Rp

PT

PTPT

L reactor

Rp

Rd

Rg

Rg

Rg

Rg

Propel 2 700 HP1400 V

XFO 1Ground

detection circuitDischarge

resistorVoltagesensor

XFO 2

Short-circuitdiode

CbD1

Cg

AFE

L reactor

L reactor

L reactor

7200 Volts - 60 Hz6600 Volts - 50 Hz

480 Volts - 60 Hz380 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

ACMotor

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 sourcevoltage

AFEreactor

AFE AC inputvoltage

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)

Lag

ging

Var

s -

Lea

ding

Var

s (p

u)

A - 81% Line VoltageB - 90% Line VoltageC - 100% Line VoltageD - 110% Line VoltageE - 0.9 Leading PF

A

BC

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

Harm

on

ic Ord

er h

Harmonic Current [ % ]

0.00%

0.05%

0.10%

0.15%

0.20%

0.25%

0.30%

0.35%

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

Harm

onic Order 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.

Siemensunitized 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 orcomutatormaintenance.

No flashover.

Fewer internal connections.

Shorter rewind lead time.

Lower rewind costs.

Acutrol III (IGBT)

BenefitsAC- 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 notune-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 notune-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 SCR�S AND GTO�S

� FEWER COMPONENTS MEANS IMPROVED RELIABILITY

IGBT MODULE

IGBT: 3300 V, 1200 AmpMotor 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 CompatibilityAcutrol 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 Successesto Future Innovations

Hydraulic Crowd BenefitsReduced Impact Loading

No Crowd Rope or Rack & Pinion Maintenance

Ease of Maintenance

Environmentally Friendly

795B795B

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-DumpLatchless Dipper

Benefits

Unique DesignPatent Applied For

Improved MTBF and MTTR

2-Pass Load 240 Ton Haul Trucks

Reduced Truck and Operator ImpactNo Latch Lever No

Latch BarNo Latch Keeper No Trip Rope

12� Dia. Cylinder

Metered Dump

Optimized Hinge Location

Provides an Additional 2.5 Feet of Dumping Height

CL

Bucyrus Loading

Advantage

42�2� Min(12.85m)

(Tail Swing = 39�)

59�2� Max(18.03m)

CAT 797CAT 797

17� window forhaul 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

Feet

195B 295B 495B 595B 795B795B795B795BTHE NEXT THE NEXT THE NEXT THE NEXT

GENERATIONGENERATIONGENERATIONGENERATION

395B