© Business Unit Metals - 1 ABB IndustrialIT solutions for
Metals.ppt
IndustrialIT solutions for
Processing Lines
ABB in Metals
© Business Unit Metals - 3 -
Topics

Drives System

Automation System (Level 1)

Manufacturing Execution System (Level 2)
© Business Unit Metals - 4 -
Topics

Drives System

Automation System (Level 1)

Manufacturing Execution System (Level 2)
Drives System for all metals applications

Applications

Hot Rolling Mills
 Cold Rolling Mills
 Profile Rolling Mills
 Processing Lines

High performance Drives

Fast torque step rise time
 High dynamic speed accuracy
 Excellent process controllability

Wide range low voltage AC Drives

© Business Unit Metals - 5 -
From 5 ... 5140 kVA, 380 ... 690 V
 Modular configuration

Stand-alone
 Multidrive (Common DC bus configuration)

Wide range DC Drives

From 22 to 5150 A DC, 380 to 1000 V AC
 Modern rebuilt kit for revamps
© Business Unit Metals - 6 -
Direct Torque Control
DTC has 25 microsecond control loop
Traditional PWM:
• Control in short steps to avoid overshooting
• Control loop time 1-3 ms because of modulator
Frequency
reference
V/F
ratio
Vector control:
• Tachometer feedback required
• Control loop time 1-3 ms because of modulator
Speed
control
Torque
control
V
Modulator
f
V
Modulator
AC
AC
f
T
DTC principle:
© Business Unit Metals - 7 -
• Torque controlled by a single step
• No risk of overshoot with fast 25 s control loop


Speed
control
Torque
control
AC
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 elasticy of shafts and inertias of motor,
gearbox and driven machine. Fast DTC attenuates the resonances.
Direct Torque Control

Advanced drives control
Torque Reference
Speed
Reference
Speed
control
Torque
Reference
Controller
REF
Torque
and Flux
Comparator
Torque
and Flux
PID
Motor Model
=
Switching
Logic
~
Switch
positions
Voltage
© Business Unit Metals - 8 -
Current
Calculated Speed
DTC CORE
3~
DTC, Direct Torque Control, fast and gentle
1,00
New Current level
Current
0,50
Servo performance
without high switching frequency
(no useless switching)
Time
0,00
Torque
© Business Unit Metals - 9 -
DTC
Vector
New Torque
level
Always to the correct value by single switching
Frequent torque monitoring prevents overshooting
Torque is always correct.
Direct Torque Control increases drive performance

Advanced drives control
Fast Torque Step Rise Time
High Dynamic Speed Accuracy
Torque
Torque
Open Loop
DTC
Speed
© Business Unit Metals - 10 -
Closed Loop
Flux vector
Open loop DTC
<5
msec
Open loop flux vector > 100
msec
Closed loop flux vector 10 to 20 msec
Speed error
Open loop DTC
0.4 %sec
Open loop flux vector 3.0 %sec
Closed loop flux vector 0.4 %sec
© Business Unit Metals - 11 -
DTC, Less stress to 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.
DTC
O ther system
Drives system reduces energy consumption

Multidrive configuration


Common DC-Bus
possible
© Business Unit Metals - 12 -
To overriding
control
Energy consumption is
reduced


DriveBus
Compensating other
loads is possible
Dimensioning of
incoming sections and
transformers or supply
can be smaller

means lower
investment
Process Section
Line Entry Section
Hardware with Modular Construction
Drive Section(s)
Supply Section
ACU
ICU
DSU
TSU
Common DC Bus
Control Section(s)
DriveBus
To overriding control
Diode or
Thyristor
Supply
Unit
~
~
AMC
AMC
1 L 1242 rpm I
SPEED 1242 rpm
CURRENT 76 A
TORQUE 86 %
1 L 1242 rpm I
SPEED 1242 rpm
CURRENT 76 A
TORQUE 86 %
Inverter
Inverter
AMC
1 L 1242 rpm I
SPEED 1242 rpm
CURRENT 76 A
TORQUE 86 %
Inverter
AMC
1 L 1242 rpm I
SPEED 1242 rpm
CURRENT 76 A
TORQUE 86 %
Inverter
PC Tools:
Drive Windows
© Business Unit Metals - 13 -
AC
© Business Unit Metals - 14 -
Intelligent Control Panel

For global use - display with
ten languages

Easy monitoring - four-line
display

Supports maintenance - fault
memory

Removable panel

Quick and easy commissioning
with the parameter copying
feature

Selection and parameterization
of application macros
Commissioning and Maintenance
© Business Unit Metals - 15 -
Drives Window Tool

Displaying system configuration

Auto tuning functions

Monitoring actual signal values

Fast and accurate measurements
with data logger

Viewing and changing parameters

Logging faults

Logging events

Local control of drives

Controlling and debugging
applications

Backup and restore
© Business Unit Metals - 16 -
Topics

Drives System

Automation System (Level 1)

Manufacturing Execution System (Level 2)
Integrated control system
Computer room
Hydraulic room
OIT & MES
Server
Control rooms (entry, proc., exit)
Switch-House
Event / Alarm
Hardcopy
...
MMS, TCP/IP
DriveBus
...
© Business Unit Metals - 17 -
Drive


...
...
Drive
Reference Generation & Seq.
Auxiliary Logic & Sequencing
Drive



Entry
...
Drive
Reference Generation & Seq.
Auxiliary Logic & Sequencing
Strip tracking, Presetting & Recording
Process
...
Drive


...
Drive
Reference Generation & Seq.
Auxiliary Logic & Sequencing
Exit
Other functions
Availability and integration of information

OperatorIT

One single interface for all applications

Data integration

© Business Unit Metals - 18 -

From production data to alarm & events
Operation efficiency
OperateIT, Keeping IT together...
Metals Customer need a way to keep together all different
aspects of plant and process entities (objects)
Simulation
Production
order
Functional
Product
Description
specification
Operator
Operator
interaction
Graphics
Stock
Cost
of
report
operation
© Business Unit Metals - 19 -
Control
Production
schedule
Production
Production
report
report
Quality
report
Profile
data
Maintenance Record
User Interface - Automatic from Object to display

You can always find out in what
graphics an object is represented

© Business Unit Metals - 20 -


Right mouse click to show the
context menu and look in the
Reference Item
Makes it possible to navigate for
examples from the

Alarm List to the graphic

Trend to the graphic

Graphic to graphic

...
Automatically configured
Process Graphics - General

State of the art process
graphics

© Business Unit Metals - 21 -

Use the latest
technology for creating
graphics
Openness

Make use of the
extensive amount of
ActiveX control available
on the market

Include any photos,
scanned images, or live
images of your choice
Special SW & HW for the needs of the rolling mill process
© Business Unit Metals - 22 -

Rolling Mill Control

Ultra fast communication between controller

Precision time marking for ms timing between duty cycles

Fast connection to pulse generator and absolute encoder

Fast Drives interface

Special program building block for efficient engineering on the
ControlIT platform
© Business Unit Metals - 23 -
ControlIT AC800 Hardware

Modular and flexible concept,
DIN-rail mounted

Scalable hardware various CPU variants

Built in RS232, ModuleBus and
redundant Ethernet

Optional communication modules

Hot swap I/O modules

Local and remote I/O options

Very low power consumption

Industry quality hardware with
excellent EMC and MTBF properties
© Business Unit Metals - 24 -
ControlIT AC 800PEC Hardware

IBM PowerPC 750FX

500 MHz

128 Mbyte RAM

16 Mbyte Flash Memory

Cycle times:

Control Builder Layer  1ms

C-Code Layer 1ms ... 100µs

VHDL Layer 100µs ... 1µs
ControlIT AC 800PEC Hardware
Any-IO, PEC 800-AIO-CEX
2 x Any-IO
CPU module, PEC 800-CPU
2 x Ethernet 100MBnd
1 x Serial RS232
© Business Unit Metals - 25 -

Up to 12 communication modules
on Any-IO CEX Bus
 2nd Any-IO can be used for e.g.
Profibus
 Up to 6 Profibus communication
Interfaces in CEX Bus
 Optical Module:

One link for Module bus for S800
or Drive communication
 Other links can be used for special
AC800PEC I/O or fast CPU point
to point communication
Optical Module, PEC 800-OM
2 x Optical Module with 3 or 6
optical links per module
Stackable up to 3 modules

Up to 7 S800 I/O clusters on the
optical ModuleBus
 Up to 12 S800 I/O modules per
cluster


7 x 12 = 84 I/O modules
Remote I/O via Profibus DP

up to 32 Stations on a Profibus
Segment
 up to 24 I/O Modules per Station
© Business Unit Metals - 26 -
ControlIT, Choose Your Language

Standard Easy to use
IEC 61131-3

All five languages supported


Instruction List (IL)

Ladder Diagram (LD)

Function Block Diagram (FBD)

Structured Text (ST)

Sequential Function Chart (SFC)
Additionally

Control Module Diagram
© Business Unit Metals - 27 -
Control Builder M

Fast, incremental, bump less
online changes

Powerful Test & Simulation

Off-line program check and
simulation

Single stepping

On-line facilities

Easy made user defined
function blocks for unmatched
flexibility

Saves Engineering work

On-line help and manuals
Make your first application in 30 minutes!
SW configuration for Processing Lines
HMI
Line Supervision
Setpoint Management
Overriding Controls
Reference Generation Emergency
Auto Slow Down
Weak Point tracking
© Business Unit Metals - 28 -
Drives Controls
Coiler Control
Roll Control
Looper Control
Roll Control
Bridle Control
Coiler Control
Roll Control
User Interface - Structure for Processing Lines
Main Menu
Start up
Start up
Conditions
Operation Mode
Mimics
Presetting
Menu
Process
Entry
Exit
Presetting
per Coil
- Entry
- Process
- Exit
Process Data
© Business Unit Metals - 29 -
Power Supply
Hydraulics
Gear Lubrication
Strip Tracking
Automatic
Operations
System-, Alarm-,
Event- & Status-Lists
Process
Entry
Exit
Start Conditions
Start conditions
Threading
Operation
(Status List)
Start Conditions
Coil Preparation
Entry, Process, Exit
Coil Transport Entry
Coil Transport Exit
Sequences
© Business Unit Metals - 30 -
Metals Solutions based on OperateIT
Process Data Display
© Business Unit Metals - 31 -
Metals Solutions based on OperateIT
Sequencing
© Business Unit Metals - 32 -
Metals Solutions based on OperateIT
Presetting & Reporting
© Business Unit Metals - 33 -
Metals Solutions based on OperateIT
Status List
Electrical Equipment for Processing Line
Continuous Processing
requires:
 For
Mechnical equipment
 Welding at Entry and cutoff at exit
 Entry and Exit Looper for coil
exchange
© Business Unit Metals - 34 -
 For Electrical Equipment
 The strip speed must be constant and
continuously adjustable within wide limits
 Acceleration / deceleration should be performed
quickly and steadily without producing any impact
forces
 The drives must always be well synchronized or
operate in groups in relative synchronism
 With 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 symmetrically 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 ……
But We Are
not only a
products
supplier,
We know
more about
metals
application
….
Line Control
Overriding control & Reference generation function
Main function:
© Business Unit Metals - 35 -






Overriding control and interlocking
Automatic sequences for threading and unthreading
Automatic slow down at pay off reel strip tail end
Strip / Weak point tracking and strip positioning
Operation mode selection
Velocity speed and dv/dt reference generation
Line Control
Strip Tracking & Setpoint Management
Main Functions:
Entry Speed 362
m/min




Weld & Weak Point Tracking
Line Section Setpoint Management
Interface with MES System
Data Recording
-100%
Process Speed 360
m/min
-50%
Exit Speed 0 m/min
-100%
-50%
© Business Unit Metals - 36 -
Furnace
-0%
Key
ABC236734677
ABC123456789
ABC898324635
XYZ6669503/1
ABC123760734
DGR89837/23Z
HDS237487453
Finishing Mill
-0%
Line Control
Coiler Drive Control
© Business Unit Metals - 37 -
Main Functions:








Basic drive application functions
Diameter calculation
Tension torque reference
Calculation of moment of inertia
Acceleration/deceleration torque compensation
Delta n acceleration compensation
Strip tail end calculation
Positioning
Line Control
Roll/Bridle Drive Control
Main Functions:
 Basic drive application functions
 Load share control function

Speed controlled drive

Speed controlled drive with window control

Speed controlled drive with droop control

Speed controlled drive with load share control
Furnace
Top Guide Roll
Dancer Roll
© Business Unit Metals - 38 -
Entry Looper
Inlet Seal Roll
Bridle 2
TM1
Exit Looper
Outlet Seal Roll
Bridle 3
TM2
Line Control
Looper drive application functions
Main Functions:
 Basic drive application functions
 Tension torque reference
© Business Unit Metals - 39 -
 Looper positioning
© Business Unit Metals - 40 -
Topics

Drives System

Automation System (Level 1)

Manufacturing Execution System (Level 2)
MES for Processing Lines
Plant Wide Planing & Reporting (ERP / SCM)
© Business Unit Metals - 41 -
Material
Identification
Production
Order
Management
Schedule
Management
Process data
acquisition
OCS (Level 1)
Combining Business Needs with the Manufacturing Process
Improving Mill-Efficiency by Real-Time Integration with ERP
Reporting
MES (Level 2) Functionality

Coil in Stock
© Business Unit Metals - 42 -
Coil Preparation
Processing
Receive Data from ERPSystem
MES (Level 2) Functionality
Coil in Stock
© Business Unit Metals - 43 -
Coil Preparation
Processing

Receive Data from ERPsystem

Production scheduling
MES (Level 2) Functionality
Coil in Stock
© Business Unit Metals - 44 -
Coil Preparation
Processing

Receive Data from ERPSystem

Production scheduling

Material Tracking
MES (Level 2) Functionality
Coil in Stock
© Business Unit Metals - 45 -
Coil Preparation
Processing

Receive Data from ERPSystem

Production scheduling

Material Tracking

Material Identification
MES (Level 2) Functionality
Coil in Stock
© Business Unit Metals - 46 -
Coil Preparation
Processing

Receive Data from ERPSystem

Production scheduling

Material Tracking

Material Identification

Preset Management
MES (Level 2) Functionality
Coil in Stock
© Business Unit Metals - 47 -
Coil Preparation
Processing

Receive Data from ERPSystem

Production scheduling

Material Tracking

Material Identification

Preset Management

Data Acquisition
MES (Level 2) Functionality
Coil in Stock
Coil Preparation
Processing

Receive Data from ERPSystem

Production scheduling

Material Tracking

Material Identification

Preset Management

Data Acquisition

Coil Reports
© Business Unit Metals - 48 -

Production Reports
MES (Level 2) Functionality
Coil in Stock
© Business Unit Metals - 49 -
Coil Preparation
Roll Change

Receive Data from ERPSystem

Production scheduling

Material Tracking

Material Identification

Preset Management

Data Acquisition

Coil Reports

Production Reports

Roll Change
MES - EquipmentManager
“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)
© Business Unit Metals - 50 -

Keep equipment available with
minimum downtime
 Maintenance triggers and alarms
 Downtime fault reports
 Operation time, start, stop are
monitored and accumulated
© Business Unit Metals - 55 -