APPLICATION SOLUTION

Bryan, Park

[Drive Team of Automation Division]

APPLICATION
SOLUTION 1] What’s Power Failure?
Power Momentary Power Failure / Momentary Voltage Drop
Failure
Solution
Drive Capacitor Voltage Drop

1] Power Loss
Low Voltage Trip within few msec and free-wheeling stop
2] Ride-Through
/ Safety Stop
3] Application-1 Motor keeps rotating by high inertia (Dangerous)

4] Application-2
All the facilities stop

Solution

Kinetic Energy Buffering Function

Various kind of Solution for Power Failure

① DC BUS Capacitor Bank
Extra
Cost ② Ultra Capacitor / Back-up Battery
③ UPS (Uninterruptible Power Supply)

④ Load Inertia (Using regenerative energy)

: Ride-Through or Safety Stop
: Keep operating without trip
APPLICATION
SOLUTION 2] Kinetic Energy Buffering (KEB)
Power Ride-Through Process
Failure Drive detects power-failure and recharges DC capacitor with regenerative energy and keeps controlling motor
Solution After main power recovers, drive accelerates motor up to target frequency again

Safety Stop Process

1] Power Loss If power-failure is too long, drive tries to decelerate the motor safely
2] Ride-Through Vdc
/ Safety Stop Recharging
U/V/W
3] Application-1 Path of
4] Application-2 Regenerative
Energy
Power R/S/T
Failure

Keep
controlling High Inertia

Maintain Output
DC-Link Voltage

Ride-Through Safety Stop

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APPLICATION
SOLUTION 2] Application-1 (Ventilation)
Power
Application with Ride-Through
Failure
Ventilating FAN systems with high inertia rate
Solution LCD or Semi-conductor manufacturing plants which need to keep controlling without trip
Some field that main power is little unstable
1] Power Loss
[Profibus-DP]
[PLC]
2] Ride-Through 3phase AC 380[V]
/ Safety Stop
3] Application-1
4] Application-2 [Operation] [Operation]
1. Run/Stop 1. Run/Stop
2. Emergency Stop 2. Emergency Stop
Bypass
3. RESET Bypass
3. RESET
4. Target Frequency 4. Target Frequency

High Inertia High Inertia

[ Key functions ]
Power Loss Vdc
① Reverse Prevention
Out Freq.
② Ride-Through

③ Lost Analog command

Out Current ④ Flying Start

⑤ Motor Overload Trip

[Actual LCD plant in Korea]

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APPLICATION
SOLUTION 2] Application-2 (Continuous winder system)
Power
Application with Safety Stop
Failure
Application that has high inertia and continuous system
Solution When power-failure occurs, all the systems have to stop safely and without product damage
Some field that main power is little unstable
1] Power Loss PLC DBU
2] Ride-Through +DBR
Main power Profibus-DP
SCR
/ Safety Stop 3phase, 380V Converter
(ACDC) DC BUS
3] Application-1
4] Application-2
90kW 45kW 11kW
KEB Signal
in power failure Encoder Encoder Encoder
M M M M
-Unwinder- -Capstan- -Traverse- -Spooler-
Master Slave Speed Torque mode
V/F mode

[ Key Functions ]
Out Current
① Safety Stop

② KEB Activation by digital input

Vdc ③ V/F torque boost

④ iS7 synchronous option card

Out Current for synchronization between capstans

[Actual winder system in China] ⑤ Motor Overload Trip

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APPLICATION SOLUTION
Press Solution
Press
System

The machine that press raw material and made up some small components

Punch
Motor

Material

Wheel
Clutch Die

Punch
Material
Die

< After pressing>

< Mechanical Press >

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Press Solution
Press
Features

When the punch impacts against the die, almost 200% of drive rated current could occur
When the punch goes up after impact, motor generates power (Over-voltage)
Due to the reason above, press need Dynamic Braking Unit and Dynamic Braking Resistor
Too much frequent operation will affect the life time of DBU, DBR
(High possibility to be damaged within 6 months)

Mechanical Press Servo Press Hydraulic Press

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2
Press Solution
Solution

Sensorless Vector Control

Sensorless mode make output current stable

 TEST Waveform for 400 tons class press

(Motor Cap. : 37kW , Drive Cap. : iS7 37kW)

  T
 

1) Ref A: 20 A 1 s
1) Ref A: 50 A 100 m s

< Press with iS7 (Output Current 1[s] > < Press with iS7 (Output Current 100[msec] >

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3
Press Solution
Solution

Regeneration avoiding

iS7 have function for controlling regenerative voltage

When motor generates energy, iS7 accelerates motor to consume the energy from the motor

Effective DC voltage control decrease DBU operation time

Life time of DBU, DBR could be longer than existing system

Output Frequency < DB 동작 억제 기능 적용 전 DB

Output Frequency
T 동작 파형 > T

 

DC Link Voltage DC Link Voltage

DBU not turned on

DBU turned on 

Overheat due to frequent operation

1) R ef A : 10 V olt 1 s
1) R ef A : 10 V olt 1 s 2) R ef B : 200 V olt 1 s
2) R ef B : 200 V olt 1 s

< Regenerating avoiding inactive > < Regenerating avoiding active >

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APPLICATION SOLUTION
APPLICATION
SOLUTION 1] Crane System
Crane
Solution Crane Overall

Crane is a kind of machine for moving heavy loads

The motions in Crane application are normally divided into Hoisting, Traveling, Traversing
1] Crane System and they have different features from each motion as below

2] Overhead Crane

3] Stacker Crane
Hoisting
Vertical motion Crane Motion
High torque at low speed Required
Sensored/Sensorless Vector Control
External Brake Control Traversing
DB Unit Required

Traveling
Forward / Backward motion Traveling
Multi-motor control
Hoisting

Traversing
Left / Right motion
Lower capacity drive required than
traveling drive

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APPLICATION
SOLUTION 1] Crane System
Crane
Solution Cranes

Cranes are usually classified into Overhead Cranes, Gantry Cranes, Harbor Cranes,
Tower Cranes, etc..
1] Crane System iS7 is normally used in Overhead Cranes and Stacker Cranes

2] Overhead Crane
Overhead Crane Harbor Crane (RMQC) Gantry Crane
3] Stacker Crane

Goliath Crane Harbor Crane (RTGC) Tower Crane

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APPLICATION
SOLUTION 1] Crane System
Crane
Solution
Simple Configuration

1] Crane System

2] Overhead Crane
Hoisting Traversing
3] Stacker Crane

Drive

Traveling
Motor

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APPLICATION
SOLUTION 2] Overhead Crane
Crane
Solution Application

App. : Crane for Coil moving (35ton)

Overall :
1] Crane System
- Hoisting, Traveling, Traversing motion required
2] Overhead Crane Solution : - Sensorless Vector Drive (110kW iS7)
- 100%ED DB Unit (280kW DB)
3] Stacker Crane

Issue & Requirements LS Solution

High Torque at low speed Applied iS7 Sensorless Vector INV

Regeneration energy Applied 280kW 100%ED DB Unit INV DBU

Mechanical Brake External Brake control function INV

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APPLICATION
SOLUTION 2] Overhead Crane
Crane
Solution
Coil moving Crane Configuration

1] Crane System
3phase 380Vac
2] Overhead Crane

3] Stacker Crane

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APPLICATION
SOLUTION 3] Stacker Crane
Crane
Solution Application

1] Crane System App. : Stacker Crane

Overall : Crane for storing boxes in warehouse
2] Overhead Crane Hoisting, Traveling, Traversing Required
Key Function : - Hoisting (High torque required)
3] Stacker Crane - Consuming regeneration
Solution : - Sensorless Vector Drive (iS7)
- DB Unit

Issue & Requirements LS Solution

High Torque at low speed Applied iS7 Sensorless Vector INV

Regeneration energy Applied 280kW 100%ED DB Unit INV DBU

Mechanical Brake External Brake control function INV

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APPLICATION
SOLUTION 3] Stacker Crane
Crane
Solution
Stacker Crane Configuration

1] Crane System

2] Overhead Crane
3phase 380Vac
3] Stacker Crane

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APPLICATION SOLUTION
 APPLICATION
SOLUTION Winder System
Winder  Winder System
Solution
Direction

1] Winder System

2] WEB Solution 1
Unwinder Rewinder
3] WEB Solution 2

4] Oil type
Winder Application
5] Continuous

6] Rewinder

7] Film Winder
Unwinder Rewinder

Open loop Closed loop Open loop Closed loop

(Sensor X) (Sensor O) (Sensor X) (Sensor O)
 Torque Control  Process PID  Torque Control  Process PID
 WEB-PID  LS WEB Open loop  WEB-PID

Solution

WEB S/W for Winder Application

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 APPLICATION
SOLUTION WEB Solution (1)
Winder  LS WEB Solution
① Diameter Calculation for stable PID control
Solution : Diameter calculation helps PID Controller to control motor more stable

1] Winder System
After
Empty Bobbin Dancer Dancer
2] WEB Solution 1
Full Bobbin
3] WEB Solution 2
② PID Start Ramp Time for reducing fluctuation at starting
4] Oil type
: PID Start Ramp reduces fluctuation of dancer of load-cell at starting
5] Continuous
Output [%] Offset
6] Rewinder

7] Film Winder Empty Bobbin Dancer

Fluctuation
t [sec.]
PID Start Ramp

③ Inertia Compensation for fluctuation

: When unwinding or winding material, bobbin gains weight. This function reduces fluctuation due to weight

Full Bobbin

P-Gain P-Gain P-Gain

[%] [%] [%]
Fluctuation
due to
gaining weight

Dancer
Time Time Time
Inertia increase [None] [Linear] [Square]

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 APPLICATION
SOLUTION WEB Solution (2)
Winder ④ Open loop control without sensors
Solution : Control motor torque limit without sensors

Direction Direction

1] Winder System Open loop

Load Cell
2] WEB Solution 1

3] WEB Solution 2 Bobbin Bobbin

4] Oil type * iV5 only

5] Continuous ⑤ Splicing for changing bobbin

: When changing bobbin, drive maintains specific tension by increasing motor speed
6] Rewinder
⑥ Traversing
7] Film Winder : Control motor to move repeatedly in specific area

Direction Bobbin
Empty Bobbin
Direction

Load Cell
Full Bobbin
Cutting

[Splicing ] [Traversing ]

⑦ Other functions
: Taper
: WEB Break
: Bobbin select

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 APPLICATION
SOLUTION Oil type
Winder Direction
[Core Size]
Solution Direction

Dancer

1] Winder System Spooler

Dies Dies (Rewinder)
2] WEB Solution 1
Cooling Oil
PID F/B
3] WEB Solution 2 [0~10V]

4] Oil type Master Drive Spooler Drive

5] Continuous
Line Speed M M
6] Rewinder Analog
Input
[4~20mA]
7] Film Winder Analog
Output
Analog
Input
[4~20mA] [4~20mA]

Line Speed Line Speed

Master Drive Spooler Drive

Issues & Requirements LS Solutions Issues & Requirements LS Solutions

Control mode Normal Speed mode Control mode WEB Speed mode

Torque at low speed Sensorless – 2 mode PID control WEB PID control

Manual operation Jog operation Different bobbin size Bobbin select function

Stop Mode DC-Brake Stop

Break WEB Break Detection

Emergency Stop Quick Stop function

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 APPLICATION
SOLUTION Continuous Winder System
Winder
Direction Direction
Solution Capstan Block Capstan Block
Bobbin

1] Winder System Dancer Dancer Dancer

2] WEB Solution 1
PID F/B
[0~10V] M PID F/B
[0~10V] M M PID F/B
[0~10V]

3] WEB Solution 2 M
4] Oil type PLC

5] Continuous

6] Rewinder
Profibus-DP
7] Film Winder First Stand Second Stand Master Spooler

First / Second Stand Spooler Drive

Issues & Requirements LS Solutions Issues & Requirements LS Solutions

Control mode WEB Speed mode Control mode WEB Speed mode
Manual Operation Jog operation PID Control WEB PID control
PID control PID Start Ramp
Various bobbin size Bobbin select function
Communication Error Lost Command function

Break WEB Break detection Break WEB Break detection

Emergency Stop Quick Stop function Emergency Stop Quick Stop function

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 APPLICATION
SOLUTION Rewinder
Winder
Solution Unwinder
Direction
Rewinder

Unwinder
Torque 방향
1] Winder System

2] WEB Solution 1 PID F/B

Encoder [0~10V]

3] WEB Solution 2 M M
4] Oil type Analog
Analog
Input Input
5] Continuous Torque
[4~20mA] [4~20mA]
Line speed
Reference DC BUS
6] Rewinder
DBU+DBR
7] Film Winder

Unwinder Rewinder

Issues & Requirements LS Solutions Issues & Requirements LS Solutions

Operation mode Torque mode Operation mode WEB Speed mode

Control mode Vector PID Control PID & Diameter Calculation

FWD/REV Operation Fwd/Rev JOG operation Various Bobbins Bobbin Selectable

Regenerative Energy DBU+DBR

Break WEB Break Detection

Emergency Stop Quick Stop

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 APPLICATION
SOLUTION Film Winder
Winder
Solution
Unwinder

Slitter
1] Winder System
Encoder
2] WEB Solution 1 Rewinder
M
3] WEB Solution 2 Analog
Input
[4~20mA]
4] Oil type Torque Analog
Reference DC BUS Input Encoder
[4~20mA]
5] Continuous Tension
Reference Analog
Input
M
6] Rewinder DBU+DBR Line Speed
[4~20mA]

7] Film Winder

Unwinder Rewinder

Issues & Requirements LS Solutions Issues & Requirements LS Solutions

Operation mode Torque mode Operation mode iV5 WEB Open loop

Control mode Vector Control Control mode Torque Limit control

Manual Operation Jog operation Various Bobbin size Bobbin Select function

Regeneration DBU+DBR
Diameter Diameter calculation

Emergency Stop Quick Stop function

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APPLICATION SOLUTION
 APPLICATION
SOLUTION Twisting System
Twisting
Solution

1] Twist System [Outside of tube] [Inside of tube] [Capstans] [Spooler]

2] Solution 1 Configuration :
1. Tube
3] Solution 2
 A lot of wires pass through the tube and the tube twists the wires
 When power loss occurs, tube must supply regenerative power to capstan and spooler for safety deceleration
 Tube must be operated at certain speed same as Capstan’s
Line direction Line direction
[Rotating tube]

[Product-Pitch]

2. Capstan / Spooler
 Capstan pulls the wires over to Spooler
 Capstan’s speed and tube’s speed must be same, otherwise the pitch will be changed (Defective Product)
 Spooler winds up the wires with certain torque

[Rotating tube] Line direction Line direction

[Pitch] [Capstan] [Spooler]

 APPLICATION
SOLUTION Solution-1
Twisting Normal system With LS Drive
Solution
Tube & Capstan

: No power loss solution : Power-loss Solution (KEB)

 The pitch can not be constant (Defective or Break)  Increase the Quality
1] Twist System
 Processing line has to stop for a while  Continuous process work
2] Solution 1
: Mechanical connection with capstan
Solution : Electrical connection with capstan
3] Solution 2
 High cost for system  Using Speed Synchronous Option
 Hard to maintain  Simple and Easy to maintain
 Low efficiency  Productivity increases

PLC
Profibus-DP

AC SCR
DC BUS
Converter
power (ACDC)
3Φ, 380V 90kW 45kW 11kW

-Capstan- -Spooler-
-Tube-
Slave Torque mode
Master
Sync. speed DBU
V/F mode
75kW

M M M
Encoder Encoder Encoder

LS Drive Twisting System configuration

 APPLICATION
SOLUTION Solution-2
Twisting Power-loss Solution (Kinetic Energy Buffering)

Solution - Application
Real Speed [Stop] : Wire

Drive Vdc - Machinery

: Twisting system

1] Twist System [Power - Time/Div

Loss] : 20sec
2] Solution 1 Current

3] Solution 2

About 120 sec.

In case of complete power-loss

Speed synchronous control (Master, Slave)

 Capstan follows tube’s speed with encoder F/B and synch. card
APPLICATION SOLUTION
APPLICATION
SOLUTION 1] Overall
Theater Upper Part
Solution

1] Overall

2] Application-1
[Prosenium] [Flying battens] [Curtain]
3] Application-2  Upper part
 Vertical motion carrying lights, screens or other stuff
4] Application-3
 Required
: DB Unit for frequent vertical operation
: Required motor capacity is normally within 30HP (22kW)
: Synchronous operation depending on the load’s features

Under Part

[Stage lifting-1] [Stage lifting-2] [Stage lifting-3]

 Under part
 Move or rotate the stage depending on the situation
 Required
: Required motor capacity is normally higher than 30HP (22kW)
: Synchronous operation depending on the situation

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APPLICATION
SOLUTION 2] Application – 1 (Flying Battens)
Theater
Solution Controller
DBU+DBR
Brake signal
Motor
Encoder F/B Encoder DRUM

1] Overall
PLC+Counter Switching HUB
2] Application-1 DBU+DBR
Electro-mechanical brake
Brake signal
Encoder F/B
3] Application-2 Motor
Encoder DRUM
4] Application-3

DBU+DBR
Brake signal
Electro-mechanical brake
Motor
Encoder F/B Encoder
DRUM

Electro-mechanical brake

 Application : Flying Batten

 Point : Position of battens is controlled by PLC Counter module (Open Collector type)
PLC calculates the position with F/B and gives an order to the drives
Issue & Requirements LS Solution

Electro-mechanical brake Brake Release Control function

Zero Speed Control Vector Control Mode
High Speed Communication Ethernet IP
Position Control PLC Counter Module
Regeneration Dynamic Braking Unit

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APPLICATION
SOLUTION 2] Application – 2 (Flying Battens)
Theater
Solution Controller DriveView7

DC BUS PLC DC BUS

1] Overall
3Phase AC
2] Application-1

3] Application-2
Switching HUB
4] Application-3
RS485 connection for speed synch.

Brake Control Brake Control

Encoder Encoder
Motor DRUM Motor DRUM

Electro-mechanical brake Electro-mechanical brake

 Application : Flying Batten

 Point : Position controlled by iS7 with Position Card (*Available soon)

Issue & Requirements LS Solution

Electro-mechanical brake Brake Release Control

Zero Speed Control Vector Control mode
High Speed Communication Ethernet IP
Position Control iS7 Position Control Option
Regeneration Dynamic Braking Unit
[iS7 Position Control Option]

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APPLICATION
SOLUTION 2] Application – 3 (Stage Curtain or Stage floor)
Theater Target [mm]
Solution Current
Position[mm]

Target [mm]
Drive 1 Drive 2 Drive 3
1] Overall

2] Application-1 Current
Current Target [mm] Position[mm]
3] Application-2 Position[mm]

4] Application-3

Switching HUB

Controller PLC DriveView7

[Proportional Synch. Position Control]

Every drives start at different points and arrive at different target point at the same time

 Application : Stage Curtain / Floor

 Point : Proportional position control by iS7 Position card

Issue & Requirements LS Solution

Electro-mechanical brake Brake Release Control

Sensorless Control Sensorless 2 mode
High Speed Communication Ethernet IP
Position Control iS7 Position Control Option

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