25.4.2016
ABB Drives
ELEC-C8001 Sähköenergiatekniikka
Anssi Sinervo
Introduction
Who is Anssi Sinervo



Master’s degree from TKK

2003–2008

Automation and Control Engineering, Electromechanics
Ph.D. Electrical engineering, Aalto University

2009–6/2013

Electromechanics, Control Engineering
Senior Engineer, ABB Drives


6/2013–
R&D, Control Software
ABB in Finland
€ 2,2
billion
5 100
Revenue
(2015)
employees
Founded
1889
1/5
Of employees
in R&D
© ABB Group
April 25, 2016 | Slide 3
Factories in Helsinki,
Vaasa, Porvoo, and Hamina
Helsinki E-factory
Pitäjänmäki

Number of employees 1200



Low voltage AC drives and
drives modules
Power range 0,18 – 5600 kW
Functions






Finland
400
Focus


In R&D
Sales and marketing
Engineering and assembly
R&D
Sourcing
Service Hub
Training
Contents
of presentation

What is a drive


Where are the drives used


What is ABB drives selling
Why would you need one
What kind of knowledge is needed to build drives

What courses should you take

What is a drive
What is ABB drives selling
What is ABB drives selling
Drive = frequency converter?
Power conversion and control
Process control
Surface level sensor
Frequency converter
Electric grid
Frequency converter + motor = drive
• Frequency converter control the motor speed …
• … and allows the control of the water level
© ABB Group
25 April 2016 | Slide 7
Frequency converter basics
Re-organizes electrical energy

AC voltage is first rectified to a constant voltage
(energy reserve)

Voltage is then chopped into small pieces that
produce the desired wave-form when filtered

Motor is controlled by changing the frequency
BU Drives and Controls
Products
LV Low Power
Drives
LV High Power
Drives
Medium Voltage
Drives
PLC and
Automation
Drives and
Controls Service
PG 4120
PG 4114
PG4117
PG 4113
PG 4159
High power AC drives
 Cabinet drives
 Servo drives and
100 - 5600 kW
motion control offering
 Multidrives
 Wall-mounted AC
1.5 - 5600 kW
drives
 Modules
1.1 - 4000 kW
 Drives designed for
 DC drives
machine building
 Modules 9 – 6 MW
 HVAC bypasses and
 Cabinet drives
drives
9 - 36 MW

Micro drives
Product Groups

General

250 kW – 7 MW
Special

purpose drives
purpose drives

Scalable PLCs

HMI control panels

Wireless Input/Output
devices
2 – 100 MW

Common configuration
software for PLC,
Drives Networks and
HMIs

Global services for the
complete life cycle

Spare parts

Technical support

Service contracts

Training
Market shares according to ARC in 2014
Total drives market
Source:
Low Power AC Drives
Worldwide Outlook –
2015 Edition, ARC
High Power AC
Drives Worldwide
Outlook – 2015
Edition, ARC
Note:
Danfoss acquired
Vacon and is not
reported separately
any longer. Clear
increase on Danfoss
market share follows
aminly from this.
Please note: For companies with less than 2% market share on any ARC product class this arithmetic total
underestimates the total market share respectively.
April 2016
Customers do not buy devices
They buy performance

Our main product to our end-users is shaft motion which
user can define

Our drives include (or we deliver separately) line controllers
that take care of grid voltage quality

We offer tools to control and monitor entire factories and
plants

Where are the drives used
Why would you need one
Why would you need one
BU Drives and Controls
Global presence
Finland,
Helsinki
Estonia,
Jüri
Poland
Lodz
USA, Wisconsin
New Berlin
China,
Beijing
Korea,
Seoul
Switzerland, Turgi
MV Drives
Malaysia,
Kuala Lumpur
Sorocaba,
Brazil
Singapore,
Central stock Asia
India,
Bangalore
Production and R&D
Worldwide R&D Centrum and Production
Central stocks
Sales
April 2016
Germany, Menden
Central stock Europe
BU Drives and Controls
Markets served
April 2016
HVAC
Food industry
Cement
Mining and minerals
Chemicals
Oil upstream
Water and waste water
Wind
Metals industry
Marine
Power generation
Pulp & Paper
Material handling
Textile
Beverage industry
Energy efficiency with ABB drives
Helping customers do more using less
About 40% of the generated electricity is consumed by
industries, and two-thirds of that energy is used by electric
motors.
Variable speed drives (VSD's) regulate the speed of a
motor and can reduce energy consumption by 30% to 50%
in many applications.
Yet, less than 10% of motors are equipped with VSD's.
Alternative is often to let motor run at full speed and
“throttle” output (which is like controlling a car’s speed by
braking while other foot is still on accelerator)
Energy efficiency in the chain
From power station to a pump application
Throttling
© ABB Group
April 25, 2016 | Slide 17
Drive controlled
Ecological payback – in one day!
Carbon footprint for manufacturing

ACS350 (7.5 kW)
54 kg CO2

ACS800 (250 kW)
910 kg CO2
Ecological payback time

ACS350 (7.5 kW)
1,1 (day)

ACS800 (250 kW)
0,5 (day)
Definition
April 2016

Manufacturing and disposal of a product consume natural resources and load the environment.

The ecological payback time is calculated as the time needed to use a product until the one-time
environmental burden caused by the product manufacturing has been compensated, thereby
reducing the environmental load. The time quoted is an estimate based on average usage of
drives.
Control is required
Drive is a must
Power to the grid
ISU (Inverter Supply Unit) applications
Water and wastewater treatment
Hundreds of motors and drives
What kind of knowledge is needed
What courses should you take
Tunnuslukuja Suomen henkilöstöstä
•
5070 henkilöä, joista toimihenkilöitä 70 %
ja työntekijöitä 30 %
•
Miehiä 80 %, naisia 20 %
•
Tekninen koulutustausta 66 %:lla
toimihenkilöistä
•
Kesäharjoittelijoita noin 890 henkilöä
•
Työssäoppijoita ja työharjoittelijoita noin 100
henkilöä
•
Valmistuneet opinnäytetyöt 167
•
Ulkomaankomennuksella vuoden aikana 148
henkilöä
•
Suomen ABB:llä ulkomaankomennuksella
vuoden aikana 51 henkilöä
•
Ulkomaalaistaustaisia henkilöitä 176
41 maasta
ABB tänään - Kohti kestävää
April
25, 2016
maailmaa
23
Tekn.tri, tekn.lis
1.0 %
Dipl.ins.
17.0 %
Muu
32.0 %
Insinööri
20.0 %
Muu
korkeak.tutk.
1,7 %
Merkonomi
3.0 %
Teknikko
6.0 %
KTM, ekon., traden.
6.0 %
Ammattikoulu
12.0 %
R&D jobs at ABB Drives
Main groups in departments


Electrical design

Software development

Main circuit

Control

Control cards

Operating system

Electrical development
(e.g. cabinets)
Mechanical development

Structural

Thermal design and
cooling

Air and water flow




1000-2000 parameters
Applications
Product development

Project management

System design

Documentation
Verifications

Testing
What should you learn while in university
Some guidelines
•
Not everyone in R&D (not to mention Sales) needs very
deep understanding in technology
•
You need to know what others are talking about (and not
just during breaks!) No one has time to teach you the
basics after you graduate
•
You need to be able to convert data given in various
formats to the format your company is using
•
Computer skills, programming, and computing
Operation point
speed
torque
power
terminal voltage
sync. gen.
voltage
current
frequency
phase resistance
phase-ind. Ld
phase-ind. Lq
1
500
820
43
33
2
5000
820
430
310
3
8200
500
430
460
4
10000
400
430
460
24
1062
25
1.4
0.06
0.069
240
1056
250
2
0.06
0.069
410
610
420
2.5
0.061
0.072
520
560
525
3
0.061
0.073
Specialize in an area that interests you!
Control software engineer requirements

Digital control (+ classic control theory)

Computer modeling (+ parameters estimation)

C/C++, python, real-time programming

Electric machine types and modeling

Power electronics (components, losses,…)

Power grid modeling

Computer (Control card) architecture, FPGA logics

Mechanical modeling basics

Thermal modeling basics

Understanding various customer applications (general
knowledge from different fields)