Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rev 5058-CO900E PUBLIC INFORMATION Drives Bootcamp Steve Littlefield, PE,PMP Power Control Area Manager Rockwell Automation Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION 2 Agenda Afternoon Sessions: • Premier Integration: • Integrated Safety • Integrated Drives • Engineering Productivity Tools - AOP’, AOI’s, and Faceplates • EtherNet IP Best Practices • Power Quality: • DySC – Dynamic Sag Correction • Power Monitoring 12:00 – 1:00 Working Lunch: • Vendor Presentations Morning Session: • AC Drives Bootcamp Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION 3 Purpose of Today’s Seminar Promote Standards and Industry Best Practices • Reduce downtime and rework due to mis-application and installation issues. • Increase Productivity • Increase Reliability • Increase Machine Availability Promote Connected Systems Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION 4 AC Drives Boot Camp Installation Considerations and Best Practices Application Considerations AC Drives AC Motors Basic Drive Physics Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rev 5058-CO900E PUBLIC INFORMATION Basic Drive Physics Steve Littlefield, PE,PMP Power Control Area Manager Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Definitions Mass “The property of a body that is a measure of its inertia ....... and results it having weight in a gravitational field Weight “The force with which a body is attracted toward the earth by gravitation and which is equal to the product of the mass by the gravitational acceleration .” F=ma Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Definitions Force “The influence that, if applied to a free body, results in an acceleration of the body .” Force has a magnitude and direction Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Definitions Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION 9 Torque “A measure of a force that tends to produce rotation and consists of the product of the force and the perpendicular distance from the line of action of the force to the axis of rotation ” Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Inertia vs Momentum 10 Inertia It is that property of matter which opposes changes in velocity. Newton’s first law of motion – A body continues its state of motion or rest in the absence of an external force. Inertia is an object’s resistance to acceleration. Inertia does not change with velocity, only with changes in mass. Momentum Is the product of inertial mass (m) and velocity (v). p=mv. Momentum is mass in motion. Momentum changes with velocity Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION System Losses 11 Friction WEIGHT / FORCE Friction Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Torque Requirements 12 FRICTION INERTIA TENSION ACCEL + + + STEADY STATE + 0 + DECEL + - + Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION What is a Radian? 13 radian = 1 radius length of arc / 1 radius length 1 revolution = 2 π rad 1 rad = 0.159155 or (2 π )-1 rev 1 rad = 57.2955780 ̊ 1 ̊ = 0.017453 rad Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION What is a Radian/Sec? 14 Angular frequency ω (Ordinary) frequency 2 π radians per second exactly 1 hertz (Hz) 1 radian per second approximately 0.159155 Hz 1 radian per second approximately 57.29578 degrees per second 1 radian per second approximately 9.5493 revolutions per minute (rpm) 0.1047 radian per second approximately 1 rpm Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION What is a Radian/sec with regard to Bandwidth/Tuning? 15 t = 1-e -1 = .63 A 1 Rad/sec response (bandwidth) = 1 t in 1 sec meaning, the actual response achieves 63% of the commanded response in 1 sec. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Radius of Gyration 16 Describes where the mass is distributed in a rotating object Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION 17 Machine Speed = 8500fpm Machine Accel Time = 60secs Steel Roll Diameter = 60” (r1 = 2.5’) Density of Steel = 490 lbs/ft 3 Width = 300” (25’) Roll Thickness = 2.5” (r2 = 2.29’) Calculating Required Torque r1 r2 ---------- Gear-in Speed ----------- Linespeed(FPM) * 12(in / ft) GIS = ----------------------------------- = 546 RPM Diameter(in) * PI Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION 18 Torque * N HPACC = ---------- = (6516 ft*lbs * 546) / 5252 = 677HP 5252 Trq(ft lbs) = 3.1416 [490)] [25] [(2.5) 4 – (2.29) 4 )] * [546 / 60] [2 ] [32.17 ft/sec 2 ] [2] 60(sec/min) Trq(ft lbs) = [ (lb/ft 3 )] [L(ft)] [(r2 4 - r1 4 ) (ft 4 )] * [ rpm / t(sec)] [2 (rad/rev)] [32.17 ft/sec 2 ] [2] 60(sec/min) Trq(ft lbs) = [38,484] [11.5] * [56.6] = 6914(lb ft sec 2 ) * .9424(rad/sec 2 ) = 6516 ft*lbs 64.34 60 Trq = [Inertia(I)] * [Angular Accel( )] Application Example Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Mechanical Drivetrain Elements 19 Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Nipped Rolls 20 Solid Steel Roll Speed Regulator Rubber Covered Roll Torque Helper