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1、ABB in Metals,IndustrialIT solutions for Processing Lines,Industrial IT for Metals Industries,Customer oriented plant-wide Industrial IT solutionsIndustrial IT Products and services for the complete plant life-cycle from concept to deliveryProducts specifically developed for Metals applicationsSeaml
2、ess integration from device to enterprise for Real-time Order Fulfillment,Topics,Drives SystemAutomation System(Level 1)Manufacturing Execution System(Level 2),Topics,Drives SystemAutomation System(Level 1)Manufacturing Execution System(Level 2),Drives System for all metals applications,Applications
3、Hot Rolling MillsCold Rolling MillsProfile Rolling Mills Processing Lines High performance DrivesFast torque step rise timeHigh dynamic speed accuracyExcellent process controllabilityWide range low voltage AC DrivesFrom 5.5140 kVA,380.690 VModular configurationStand-alone Multidrive(Common DC bus co
4、nfiguration)Wide range DC DrivesFrom 22 to 5150 A DC,380 to 1000 V ACModern rebuilt kit for revamps,Direct Torque Control,DTC has 25 microsecond control loop,Traditional PWM:Control in short steps to avoid overshootingControl loop time 1-3 ms because of modulator,V,f,Frequency reference,Modu-lator,V
5、/F ratio,AC,Speed control,Torque control,AC,V,f,Torque control,Modu-lator,Speed control,AC,T,Vector control:Tachometer feedback requiredControl loop time 1-3 ms because of modulator,DTC principle:Torque controlled by a single step No risk of overshoot with fast 25 s control loop,Backlash appears in
6、gearboxes and couplings.In backlash range motor may accelerate leading to backlash impact.Fast DTC control limits impact.Mechanical resonances often appear due to elasticy of shafts and inertias of motor,gearbox and driven machine.Fast DTC attenuates the resonances.,Direct Torque Control,Advanced dr
7、ives control,DTC,Direct Torque Control,fast and gentle,Always to the correct value by single switchingFrequent torque monitoring prevents overshootingTorque is always correct.,Servo performancewithout high switching frequency(no useless switching),Open loop DTC100msecClosed loop flux vector10 to 20m
8、sec,Fast Torque Step Rise Time,Closed Loop Flux vector,Open Loop DTC,Torque,High Dynamic Speed Accuracy,Speed,Torque,Speed error,Open loop DTC0.4%secOpen loop flux vector3.0%secClosed loop flux vector 0.4%sec,Direct Torque Control increases drive performance,Advanced drives control,DTC,Less stress t
9、o mechanics,Backlash appears in gearboxes and couplings.In backlash range motor may accelerate leading to backlash impact.Fast DTC control limits impact.Mechanical resonances often appear due to elasticity of shafts and inertias of motor,gearbox and driven machine.Fast DTC attenuates the resonances.
10、,Drives system reduces energy consumption,Multidrive configurationCommon DC-Bus possibleEnergy consumption is reducedCompensating other loads is possibleDimensioning of incoming sections and transformers or supply can be smallermeans lower investment,Hardware with Modular Construction,Intelligent Co
11、ntrol Panel,For global use-display with ten languagesEasy monitoring-four-line displaySupports maintenance-fault memoryRemovable panelQuick and easy commissioning with the parameter copying featureSelection and parameterization of application macros,Commissioning and Maintenance,Drives Window ToolDi
12、splaying system configurationAuto tuning functionsMonitoring actual signal valuesFast and accurate measurements with data logger Viewing and changing parametersLogging faultsLogging eventsLocal control of drivesControlling and debugging applicationsBackup and restore,Topics,Drives SystemAutomation S
13、ystem(Level 1)Manufacturing Execution System(Level 2),Integrated control system,OIT&MES Server,Reference Generation&Seq.Auxiliary Logic&Sequencing,EntryProcessExitOther functions,Computer room,Control rooms(entry,proc.,exit),Hydraulic room,Switch-House,Hardcopy,Event/Alarm,Reference Generation&Seq.A
14、uxiliary Logic&SequencingStrip tracking,Presetting&Recording,Reference Generation&Seq.Auxiliary Logic&Sequencing,.,DriveBus,MMS,TCP/IP,Availability and integration of information,OperatorITOne single interface for all applicationsData integrationFrom production data to alarm&eventsOperation efficien
15、cy,OperateIT,Keeping IT together.,Metals Customer need a way to keep together all different aspects of plant and process entities(objects),You can always find out in what graphics an object is representedRight mouse click to show the context menu and look in the Reference ItemMakes it possible to na
16、vigate for examples from theAlarm List to the graphicTrend to the graphicGraphic to graphic.Automatically configured,User Interface-Automatic from Object to display,State of the art process graphicsUse the latest technology for creating graphicsOpennessMake use of the extensive amount of ActiveX con
17、trol available on the marketInclude any photos,scanned images,or live images of your choice,Process Graphics-General,Special SW&HW for the needs of the rolling mill process,Rolling Mill ControlUltra fast communication between controllerPrecision time marking for ms timing between duty cyclesFast con
18、nection to pulse generator and absolute encoderFast Drives interfaceSpecial program building block for efficient engineering on the ControlIT platform,ControlIT AC800 Hardware,Modular and flexible concept,DIN-rail mountedScalable hardware-various CPU variantsBuilt in RS232,ModuleBus and redundant Et
19、hernetOptional communication modulesHot swap I/O modulesLocal and remote I/O optionsVery low power consumptionIndustry quality hardware with excellent EMC and MTBF properties,ControlIT AC 800PEC Hardware,IBM PowerPC 750FX500 MHz 128 Mbyte RAM 16 Mbyte Flash MemoryCycle times:Control Builder Layer 1m
20、s C-Code Layer 1ms.100s VHDL Layer 100s.1s,ControlIT AC 800PEC Hardware,Up to 12 communication modules on Any-IO CEX Bus2nd Any-IO can be used for e.g.ProfibusUp to 6 Profibus communication Interfaces in CEX BusOptical Module:One link for Module bus for S800 or Drive communicationOther links can be
21、used for special AC800PEC I/O or fast CPU point to point communication,Up to 7 S800 I/O clusters on the optical ModuleBusUp to 12 S800 I/O modules per cluster7 x 12=84 I/O modulesRemote I/O via Profibus DPup to 32 Stations on a Profibus Segmentup to 24 I/O Modules per Station,Optical Module,PEC 800-
22、OM2 x Optical Module with 3 or 6 optical links per module Stackable up to 3 modules,CPU module,PEC 800-CPU2 x Ethernet 100MBnd1 x Serial RS232,Any-IO,PEC 800-AIO-CEX2 x Any-IO,ControlIT,Choose Your Language,Standard Easy to use IEC 61131-3All five languages supportedInstruction List(IL)Ladder Diagra
23、m(LD)Function Block Diagram(FBD)Structured Text(ST)Sequential Function Chart(SFC)Additionally Control Module Diagram,Control Builder M,Fast,incremental,bump less online changesPowerful Test&SimulationOff-line program check and simulationSingle steppingOn-line facilities Easy made user defined functi
24、on blocks for unmatched flexibilitySaves Engineering workOn-line help and manuals,Make your first application in 30 minutes!,SW configuration for Processing Lines,User Interface-Structure for Processing Lines,Power SupplyHydraulicsGear Lubrication,Operation Mode,Process Data,Start Conditions,Strip T
25、racking,Automatic Operations,Presetting Menu,System-,Alarm-,Event-&Status-Lists,Start Conditions,Sequences,Coil PreparationEntry,Process,ExitCoil Transport EntryCoil Transport Exit,Main Menu,Start up,Mimics,(Status List),Start up Conditions,Presettingper Coil-Entry-Process-Exit,Metals Solutions base
26、d on OperateIT,Process Data Display,Metals Solutions based on OperateIT,Sequencing,Metals Solutions based on OperateIT,Presetting&Reporting,Metals Solutions based on OperateIT,Status List,Electrical Equipment for Processing Line,But We Are not only a products supplier,We know more about metals appli
27、cation.,For Mechnical equipmentWelding at Entry and cutoff at exitEntry and Exit Looper for coil exchange,Continuous Processing requires:,For Electrical EquipmentThe strip speed must be constant and continuously adjustable within wide limits Acceleration/deceleration should be performed quickly and
28、steadily without producing any impact forces The drives must always be well synchronized or operate in groups in relative synchronismWith defined tension distribution,which can be adjusted at certain groups in the strip processing line,the strip has to be moved over long distances and many rolls sym
29、metrically to the axis of the line The tension has to be produced by part of motor running in motoring mode and part of motor running in generating mode.And More,Overriding control&Reference generation function,Line Control,Main function:Overriding control and interlockingAutomatic sequences for thr
30、eading and unthreadingAutomatic slow down at pay off reel strip tail endStrip/Weak point tracking and strip positioningOperation mode selectionVelocity speed and dv/dt reference generation,Strip Tracking&Setpoint Management,Weld&Weak Point TrackingLine Section Setpoint ManagementInterface with MES S
31、ystemData Recording,Main Functions:,Line Control,Coiler Drive Control,Basic drive application functionsDiameter calculationTension torque referenceCalculation of moment of inertiaAcceleration/deceleration torque compensationDelta n acceleration compensationStrip tail end calculationPositioning,Line
32、Control,Main Functions:,Roll/Bridle Drive Control,Basic drive application functionsLoad share control functionSpeed controlled driveSpeed controlled drive with window controlSpeed controlled drive with droop controlSpeed controlled drive with load share control,Main Functions:,Line Control,Looper dr
33、ive application functions,Basic drive application functionsTension torque referenceLooper positioning,Main Functions:,Line Control,Topics,Drives SystemAutomation System(Level 1)Manufacturing Execution System(Level 2),MES for Processing Lines,Combining Business Needs with the Manufacturing ProcessImp
34、roving Mill-Efficiency by Real-Time Integration with ERP,OCS(Level 1),Production OrderManagement,MaterialIdentification,Schedule Management,Process dataacquisition,Reporting,Plant Wide Planing&Reporting(ERP/SCM),MES(Level 2)Functionality,Receive Data from ERP-System,Coil in Stock,Coil Preparation,Pr
35、ocessing,Receive Data from ERP-systemProduction scheduling,Coil in Stock,Coil Preparation,Processing,MES(Level 2)Functionality,Receive Data from ERP-SystemProduction schedulingMaterial Tracking,Coil in Stock,Coil Preparation,Processing,MES(Level 2)Functionality,Receive Data from ERP-SystemProduction
36、 schedulingMaterial TrackingMaterial Identification,Coil in Stock,Coil Preparation,Processing,MES(Level 2)Functionality,Receive Data from ERP-SystemProduction schedulingMaterial TrackingMaterial IdentificationPreset Management,Coil in Stock,Coil Preparation,Processing,MES(Level 2)Functionality,Recei
37、ve Data from ERP-SystemProduction schedulingMaterial TrackingMaterial IdentificationPreset ManagementData Acquisition,Coil in Stock,Coil Preparation,Processing,MES(Level 2)Functionality,Receive Data from ERP-SystemProduction schedulingMaterial TrackingMaterial IdentificationPreset ManagementData Acq
38、uisitionCoil Reports,Coil in Stock,Coil Preparation,Processing,Production Reports,MES(Level 2)Functionality,Receive Data from ERP-SystemProduction schedulingMaterial TrackingMaterial IdentificationPreset ManagementData AcquisitionCoil Reports,Coil in Stock,Coil Preparation,Roll Change,Production Rep
39、ortsRoll Change,MES(Level 2)Functionality,“The operational goal is to keep plant,equipment and facilities available with minimum downtime at minimum cost to maximize revenue and profit”(Source:Gartner Group),MES-EquipmentManager,Keep equipment available with minimum downtime Maintenance triggers and
40、 alarmsDowntime fault reportsOperation time,start,stop are monitored and accumulated,Topics,Drives systemAutomation System(Level 1)Manufacturing Execution System(Level 2)Results,Line Control Practical Results,Controlling the tension in a Processing Line to very high accuracyCoordination of up to 200
41、 drives,Tension during coil change at entryFirst diagram:fil_tens_TM4act.tension(between cleaning and tinning)fil_tens_TM6act.tension(behind melting)Second diagram:fil_tens_TM1Entry looper tensionfil_tens_TM2Leveller tension(side trimmer)fil_tens_TM3Bridle 2 tension(entry of cleaning)fil_tens_TM5Bri
42、dle 3 tensionfil_tens_TM7Exit looper tensionThird diagram:vbr1r2_FILTAct.velocity entryvbr4r2_FILTAct.velocity processvbr5r1_FILTAct.velocity exit,Tension during coil change at entry and exit First diagram:fil_tens_TM4act.tension(between cleaning and tinning)fil_tens_TM6act.tension(behind melting)Second diagram:fil_tens_TM1Entry looper tensionfil_tens_TM2Leveller tension(side trimmer)fil_tens_TM3Bridle 2 tension(entry of cleaning)fil_tens_TM5Bridle 3 tensionfil_tens_TM7Exit looper tensionThird diagram:vbr1r2_FILTAct.velocity entryvbr4r2_FILTAct.velocity processvbr5r1_FILTAct.velocity exit,
