ABB+IndustrialIT+solutions+for+Processing+Lines.ppt

abbinmetals,industrialitsolutionsforprocessinglines,industrialitformetalsindustries,customerorientedplant-wideindustrialitsolutionsindustrialitproductsandservicesforthecompleteplantlife-cyclefromconcepttodeliveryproductsspecificallydevelopedformetalsapplicationsseamlessintegrationfromdevicetoenterpriseforreal-timeorderfulfillment,topics,drivessystemautomationsystem(level1)manufacturingexecutionsystem(level2),topics,drivessystemautomationsystem(level1)manufacturingexecutionsystem(level2),drivessystemforallmetalsapplications,applicationshotrollingmillscoldrollingmillsprofilerollingmillsprocessinglineshighperformancedrivesfasttorquesteprisetimehighdynamicspeedaccuracyexcellentprocesscontrollabilitywiderangelowvoltageacdrivesfrom5.5140kva,380.690vmodularconfigurationstand-alonemultidrive(commondcbusconfiguration)widerangedcdrivesfrom22to5150adc,380to1000vacmodernrebuiltkitforrevamps,directtorquecontrol,dtchas25microsecondcontrolloop,traditionalpwm:controlinshortstepstoavoidovershootingcontrollooptime1-3msbecauseofmodulator,v,f,frequencyreference,modu-lator,v/fratio,ac,speedcontrol,torquecontrol,ac,v,f,torquecontrol,modu-lator,speedcontrol,ac,t,vectorcontrol:tachometerfeedbackrequiredcontrollooptime1-3msbecauseofmodulator,dtcprinciple:torquecontrolledbyasinglestepnoriskofovershootwithfast25scontrolloop,backlashappearsingearboxesandcouplings.inbacklashrangemotormayaccelerateleadingtobacklashimpact.fastdtccontrollimitsimpact.mechanicalresonancesoftenappearduetoelasticyofshaftsandinertiasofmotor,gearboxanddrivenmachine.fastdtcattenuatestheresonances.,directtorquecontrol,advanceddrivescontrol,dtc,directtorquecontrol,fastandgentle,alwaystothecorrectvaluebysingleswitchingfrequenttorquemonitoringpreventsovershootingtorqueisalwayscorrect.,servoperformancewithouthighswitchingfrequency(nouselessswitching),openloopdtc100msecclosedloopfluxvector10to20msec,fasttorquesteprisetime,closedloopfluxvector,openloopdtc,torque,highdynamicspeedaccuracy,speed,torque,speederror,openloopdtc0.4%secopenloopfluxvector3.0%secclosedloopfluxvector0.4%sec,directtorquecontrolincreasesdriveperformance,advanceddrivescontrol,dtc,lessstresstomechanics,backlashappearsingearboxesandcouplings.inbacklashrangemotormayaccelerateleadingtobacklashimpact.fastdtccontrollimitsimpact.mechanicalresonancesoftenappearduetoelasticityofshaftsandinertiasofmotor,gearboxanddrivenmachine.fastdtcattenuatestheresonances.,drivessystemreducesenergyconsumption,multidriveconfigurationcommondc-buspossibleenergyconsumptionisreducedcompensatingotherloadsispossibledimensioningofincomingsectionsandtransformersorsupplycanbesmallermeanslowerinvestment,hardwarewithmodularconstruction,intelligentcontrolpanel,forglobaluse-displaywithtenlanguageseasymonitoring-four-linedisplaysupportsmaintenance-faultmemoryremovablepanelquickandeasycommissioningwiththeparametercopyingfeatureselectionandparameterizationofapplicationmacros,commissioningandmaintenance,driveswindowtooldisplayingsystemconfigurationautotuningfunctionsmonitoringactualsignalvaluesfastandaccuratemeasurementswithdataloggerviewingandchangingparametersloggingfaultsloggingeventslocalcontrolofdrivescontrollinganddebuggingapplicationsbackupandrestore,topics,drivessystemautomationsystem(level1)manufacturingexecutionsystem(level2),integratedcontrolsystem,oit&messerver,referencegeneration&seq.auxiliarylogic&sequencing,entryprocessexitotherfunctions,computerroom,controlrooms(entry,proc.,exit),hydraulicroom,switch-house,hardcopy,event/alarm,referencegeneration&seq.auxiliarylogic&sequencingstriptracking,presetting&recording,referencegeneration&seq.auxiliarylogic&sequencing,.,drivebus,mms,tcp/ip,availabilityandintegrationofinformation,operatoritonesingleinterfaceforallapplicationsdataintegrationfromproductiondatatoalarm&eventsoperationefficiency,operateit,keepingittogether.,metalscustomerneedawaytokeeptogetheralldifferentaspectsofplantandprocessentities(objects),youcanalwaysfindoutinwhatgraphicsanobjectisrepresentedrightmouseclicktoshowthecontextmenuandlookinthereferenceitemmakesitpossibletonavigateforexamplesfromthealarmlisttothegraphictrendtothegraphicgraphictographic.automaticallyconfigured,userinterface-automaticfromobjecttodisplay,stateoftheartprocessgraphicsusethelatesttechnologyforcreatinggraphicsopennessmakeuseoftheextensiveamountofactivexcontrolavailableonthemarketincludeanyphotos,scannedimages,orliveimagesofyourchoice,processgraphics-general,specialsw&hwfortheneedsoftherollingmillprocess,rollingmillcontrolultrafastcommunicationbetweencontrollerprecisiontimemarkingformstimingbetweendutycyclesfastconnectiontopulsegeneratorandabsoluteencoderfastdrivesinterfacespecialprogrambuildingblockforefficientengineeringonthecontrolitplatform,controlitac800hardware,modularandflexibleconcept,din-railmountedscalablehardware-variouscpuvariantsbuiltinrs232,modulebusandredundantethernetoptionalcommunicationmoduleshotswapi/omoduleslocalandremotei/ooptionsverylowpowerconsumptionindustryqualityhardwarewithexcellentemcandmtbfproperties,controlitac800pechardware,ibmpowerpc750fx500mhz128mbyteram16mbyteflashmemorycycletimes:controlbuilderlayer1msc-codelayer1ms.100svhdllayer100s.1s,controlitac800pechardware,upto12communicationmodulesonany-iocexbus2ndany-iocanbeusedfore.g.profibusupto6profibuscommunicationinterfacesincexbusopticalmodule:onelinkformodulebusfors800ordrivecommunicationotherlinkscanbeusedforspecialac800peci/oorfastcpupointtopointcommunication,upto7s800i/oclustersontheopticalmodulebusupto12s800i/omodulespercluster7x12=84i/omodulesremotei/oviaprofibusdpupto32stationsonaprofibussegmentupto24i/omodulesperstation,opticalmodule,pec800-om2xopticalmodulewith3or6opticallinkspermodulestackableupto3modules,cpumodule,pec800-cpu2xethernet100mbnd1xserialrs232,any-io,pec800-aio-cex2xany-io,controlit,chooseyourlanguage,standardeasytouseiec61131-3allfivelanguagessupportedinstructionlist(il)ladderdiagram(ld)functionblockdiagram(fbd)structuredtext(st)sequentialfunctionchart(sfc)additionallycontrolmodulediagram,controlbuilderm,fast,incremental,bumplessonlinechangespowerfultest&simulationoff-lineprogramcheckandsimulationsinglesteppingon-linefacilitieseasymadeuserdefinedfunctionblocksforunmatchedflexibilitysavesengineeringworkon-linehelpandmanuals,makeyourfirstapplicationin30minutes!,swconfigurationforprocessinglines,userinterface-structureforprocessinglines,powersupplyhydraulicsgearlubrication,operationmode,processdata,startconditions,striptracking,automaticoperations,presettingmenu,system-,alarm-,event-&status-lists,startconditions,sequences,coilpreparationentry,process,exitcoiltransportentrycoiltransportexit,mainmenu,startup,mimics,(statuslist),startupconditions,presettingpercoil-entry-process-exit,metalssolutionsbasedonoperateit,processdatadisplay,metalssolutionsbasedonoperateit,sequencing,metalssolutionsbasedonoperateit,presetting&reporting,metalssolutionsbasedonoperateit,statuslist,electricalequipmentforprocessingline,butwearenotonlyaproductssupplier,weknowmoreaboutmetalsapplication.,formechnicalequipmentweldingatentryandcutoffatexitentryandexitlooperforcoilexchange,continuousprocessingrequires:,forelectricalequipmentthestripspeedmustbeconstantandcontinuouslyadjustablewithinwidelimitsacceleration/decelerationshouldbeperformedquicklyandsteadilywithoutproducinganyimpactforcesthedrivesmustalwaysbewellsynchronizedoroperateingroupsinrelativesynchronismwithdefinedtensiondistribution,whichcanbeadjustedatcertaingroupsinthestripprocessingline,thestriphastobemovedoverlongdistancesandmanyrollssymmetricallytotheaxisofthelinethetensionhastobeproducedbypartofmotorrunninginmotoringmodeandpartofmotorrunningingeneratingmode.andmore,overridingcontrol&referencegenerationfunction,linecontrol,mainfunction:overridingcontrolandinterlockingautomaticsequencesforthreadingandunthreadingautomaticslowdownatpayoffreelstriptailendstrip/weakpointtrackingandstrippositioningoperationmodeselectionvelocityspeedanddv/dtreferencegeneration,striptracking&setpointmanagement,weld&weakpointtrackinglinesectionsetpointmanagementinterfacewithmessystemdatarecording,mainfunctions:,linecontrol,coilerdrivecontrol,basicdriveapplicationfunctionsdiametercalculationtensiontorquereferencecalculationofmomentofinertiaacceleration/decelerationtorquecompensationdeltanaccelerationcompensationstriptailendcalculationpositioning,linecontrol,mainfunctions:,roll/bridledrivecontrol,basicdriveapplicationfunctionsloadsharecontrolfunctionspeedcontrolleddrivespeedcontrolleddrivewithwindowcontrolspeedcontrolleddrivewithdroopcontrolspeedcontrolleddrivewithloadsharecontrol,mainfunctions:,linecontrol,looperdriveapplicationfunctions,basicdriveapplicationfunctionstensiontorquereferencelooperpositioning,mainfunctions:,linecontrol,topics,drivessystemautomationsystem(level1)manufacturingexecutionsystem(level2),mesforprocessinglines,combiningbusinessneedswiththemanufacturingprocessimprovingmill-efficiencybyreal-timeintegrationwitherp,ocs(level1),productionordermanagement,materialidentification,schedulemanagement,processdataacquisition,reporting,plantwideplaning&reporting(erp/scm),mes(level2)functionality,receivedatafromerp-system,coilinstock,coilpreparation,processing,receivedatafromerp-systemproductionscheduling,coilinstock,coilpreparation,processing,mes(level2)functionality,receivedatafromerp-systemproductionschedulingmaterialtracking,coilinstock,coilpreparation,processing,mes(level2)functionality,receivedatafromerp-systemproductionschedulingmaterialtrackingmaterialidentification,coilinstock,coilpreparation,processing,mes(level2)functionality,receivedatafromerp-systemproductionschedulingmaterialtrackingmaterialidentificationpresetmanagement,coilinstock,coilpreparation,processing,mes(level2)functionality,receivedatafromerp-systemproductionschedulingmaterialtrackingmaterialidentificationpresetmanagementdataacquisition,coilinstock,coilpreparation,processing,mes(level2)functionality,receivedatafromerp-systemproductionschedulingmaterialtrackingmaterialidentificationpresetmanagementdataacquisitioncoilreports,coilinstock,coilpreparation,processing,productionreports,mes(level2)functionality,receivedatafromerp-systemproductionschedulingmaterialtrackingmaterialidentificationpresetmanagementdataacquisitioncoilreports,coilinstock,coilpreparation,rollchange,productionreportsrollchange,mes(level2)functionality,“theoperationalgoalistokeepplant,equipmentandfacilitiesavailablewithminimumdowntimeatminimumcosttomaximizerevenueandprofit”(source:gartnergroup),mes-equipmentmanager,keepequipme