Nidec Industrial Solutions Applying Encoders in Mining

Nidec Industrial Solutions Applying Encoders in Mining

Nidec Industrial Solutions EXTREME MACHINES THROUGHOUT THE WORLD Mining Marine Metals Cranes Energy: Wind, Oil, & Gas Forest Products Introduction to Nidec Avtron Automation March 19, 2014; Company Confidential 2

What do we make? Drives, Motors, DC Power Supply, Encoders, and Systems AC Drives DC Drives SR Drives Motors Encoders MV Drives Drive Systems 3

Nidec-Avtron s Mining Background 1991 1 st P&H120A Blasthole Drill 1994 1 st Mine Hoist 1996 P&H Shovels Developed 1 st Digital DC Drive for P&H shovels, and RPC rolling bank feature 1998 1 st Dragline Upgrade 2000s Multiple shovel and dragline upgrades 2015 Sold 250 th Mining Drive Control System Introduction to Nidec Avtron Automation March 19, 2014; Company Confidential 4

Drive Systems and Service Capabilities and Expertise Project Management Design Engineering Installation, Startup, and Commissioning Services Custom enclosures and packaging Drive retrofit solutions PLC application and programming HMI application and programming Dedicated diagnostic systems Power quality studies Remote Machine Monitoring Training 5

Mining Industry Experience Draglines Shovels Blasthole Drills Introduction to Nidec Avtron Automation March 19, 2014; Company Confidential 6 6

Mining Industry Experience Overhead Cranes Rectifiers Overland Conveyors Mine Hoists Introduction to Nidec Avtron Automation March 19, 2014; Company Confidential 7 7

Tom Miller background Plank owner on either USS Langley or USS Nimitz not sure which. 8

As a young sailor, Tom learned the importance of good wiring and troubleshooting He swears he didn t cause this 9

Applying Encoders in Mining Tom Miller Nidec Avtron Automation Corporation May 28, 2015 10

Speed and Position Sensors Speed Sensors Signals What goes wrong Troubleshooting What can you do? Position Sensors Signals What goes wrong Troubleshooting What can you do? 11

Where are encoders used in mining? AC drives on excavators Conveyors Crushers Mills Cranes Anywhere you use an AFE, or need precise speed feedback 12

Speed and Position Sensors What s in this presentation? Incremental encoders/pulse tachs Absolute encoders Hardware Wiring What s not in this presentation? Resolvers Software 13

Types of Feedback Devices Analog Tachogenerators Linear Voltage Output, 50/100/200vDC/1000rpm and 45/90vAC Reluctance Pulse Generators Sine wave output, 120-360ppr Optical Encoders Square wave output, 1-5000ppr Magneto-resistive Encoders Square wave output, 1-5000ppr Absolute Encoders Binary word output Resolvers Sin/Cos output providing speed and position using R/D Converters 14

Speed and Position Sensors Incremental Encoder Signals 15

Encoder troubleshooting What is a good output? Speed Sensor Signals 16

Is this OK? Speed Sensor Signals 17

Is this OK? Speed Sensor Signals 18

Is this OK? Speed Sensor Signals 19

Is this OK? Speed Sensor Signals 20

Is this OK? Speed Sensor Signals 21

What Goes Wrong-Incremental Encoders Sensor Line driver Field wiring 22

Troubleshooting Incremental Encoders Oscilloscope Do you have a differential isolated probe Get Vendor Diagnostics Simpler Predictive No dedicated devices 23

Incremental Encoders/Speed Sensors: What Can You Do? Eliminate bearings Flanges can be added to any motor! Units with removable sensors Potted electronics Wiring protection Use good cable/premade 24

Absolute Encoders - Position Sensors Someone s picked your bus! SSI Profibus ProfiNet DeviceNet EtherNet/IP Modbus TCP EnDAT Hiperface Parallel Trademarks are the property of their owners 25

Position Sensors Position Sensor Signals: Classic Absolute Parallel Output Image Source: http://teledynelecroy.com 26

Position Sensors You need smart tools to troubleshoot networks with an oscilloscope Image Source: http://teledynelecroy.com 27

Position Sensors Most absolute encoder networks use high-level tools for troubleshooting Image Source: controlengineering.com 28

Position Sensors So what do you look for when troubleshooting position sensors? Devices have several LEDs IP address tools Master controller tools Read the manual out of desperation 29

What Goes Wrong - Absolute Encoders Sensors Line driver Gearing Bearings Field wiring Bus settings 30

Position Sensors- Absolute Encoders What Can You Do to Extend Life? Get bigger bearing units Eliminate geared units Broad voltage tolerances Avoid proprietary busses Simple diagnostics Use structured wiring systems 31

Underway Replenishment 32

P&H 4100XPC Avtron AV125 Encoder 33

Excavator Encoder Problem Mine had reliability, cost, and delivery issues with existing encoder on shovel Mine was replacing encoders twice a year, failing without warning, causing unwanted electrical downtime Cost was high enough to require capital budgeting for encoders unacceptable Delivery of replacement unit - up to 12 weeks from Europe 34

Solution and Result Mine contacted Avtron for assistance Avtron came to mine and measured existing motor to determine optimum solution, considered either AV125 flange mount unit, or AV685 shaft mount. Chose shaft mount solution due to ease of mounting adapter shaft Result: Have not had an encoder failure since installation last year. Complete upgrade was 20% of previous unit cost with adapter shaft, shipment of US-made unit is 24-48 hours. 35

BE495 Crowd Encoder Introduction to Nidec Avtron Automation March 19, 2014; Company Confidential 36

BE495 Swing Encoder Introduction to Nidec Avtron Automation March 19, 2014; Company Confidential 37

Position and Speed Sensors Wrap-Up and More Questions? 38