PROJECT REPORT ONTO STUDY DC MOTOR CONTROL TECHNIQUES(DC DRIVES) WITH SPECIAL INFUSES ONAVTRON DRIVES.

BRIEF PROFILE OF THE COMPANYELECTRIC MOTORSTYPES OF MOTORSSPEED CONTROL OF DC MOTOR

CONTENTMOTOR GENERATOR SETINTRODUCTION TO ELECTRIC DRIVES

BLOCK DIAGRAM OF DC MOTOR CONTROLFACTORS AFFECTING DC DRIVE SELECTIONVARIABLE DC DRIVEADJUSTABLE SPEED DRIVEREASONS FOR USING ADJUSTABLE SPEED DRIVETYPES OF DRIVESADVANTAGES -32 DC DRIVE FAMILYFLEXIBILITY AND CONTROLPURPOSEAPPLICATIONSSTANDARD FEATURE SUMMARYCONCLUSION

CONTENT

With the ongoing technical revolution where innovations are taking place at the blink of an eye, it is impossible to keep the pace with the emerging trends. In organization where making things right in the first instances is the driving motto, perfection and inaccuracy is inevitable.

Excellence is an attitude that the whole of the human race is born with. It is the environment that makes sure that whether the result of this attitude is visible or otherwise. A Well-planned properly executed and evaluated industrial training helps a lot in inculcating a professional attitude. It Provides a linkage between the student and industry to develop an awareness of industrial approach to problem solving ,based on a broad understanding.

PREFACE

ACKNOWLEDGEMENT Before focusing on my report WE would like to thank few people who made this report come true. First of all we would like to thank Mr. ARUN SINGH, MED ELECTRICAL for providing help as desired from time to time. who guided and encourage me. I am very grateful for their help and support. I would like to thank my parents & project co-ordinator for their help and moral support. Last but not the least, all the workers out there for their tit-bit of information. This report deals with important component of the plant and their working. It adds detail from the processing of MOTOR CONTROL to the AVTRON drives. This report reflects the experience I have gained during the vocational training at Tata Steel Ltd. Jamshedpur.

last but not the least I also want to thanks our RESPECTED principal MR. K.V.NAIR our HOD MRS.PREETA JHON and our section in charge MR.APURVA RANJAN PATRA .who have given the chance to do industrial project in multilevel company TATA STEEL

ABOUT TATA STEELEstablished in 1907 as Asia's first integrated private sector steel company, Tata Steel Group is among the top-ten global steel companies with an annual crude steel capacity of over 29 million tones per annum. It is now the world's second-most geographically-diversified steel producer, with operations in 26 countries and a commercial presence in over 50 countries. The Tata Steel Group, with a turnover of US$ 24.82 billion in FY 13, has over 80,000 employees across five continents and is a Fortune 500 company. Tata Steels larger production facilities comprise those in India, the UK, the Netherlands, Thailand, Singapore, China and Australia. Operating companies within the Group include Tata Steel Limited (India), Tata Steel Europe Limited (formerly Corus), Tata Steel Singapore and Tata Steel Thailand.The Tata Steel Groups vision is to be the worlds steel industry benchmark in Value Creation and Corporate Citizenship through the excellence of its people, its innovative approach and overall conduct. Underpinning this vision is a performance culture committed to aspiration targets, safety and social responsibility, continuous improvement, openness and transparency.

BRIEF PROFILE OF THE COMPANY

MotorsMotors convert electrical energy to mechanical energyMotors make things move LINEARELECTROSTATICDC BRUSHSTEPPERINDUCTIONUNIVERSAL

Other kinds of electric motors

In ordinary DC motors, like the ones we've just considered, the rotor spins inside the stator. AC motors work a slightly different way: they pass alternating current through opposing pairs of magnets to create a rotating magnetic field, which "induces" (creates) a magnetic field in the motor's rotor, causing it to spin around. You can read more about this in our article on AC induction motors. If you take one of these induction motors and "unwrap" it, so the stator is effectively laid out into a long continuous track, the rotor can roll along it in a straight line. This ingenious design is known as a linear motor, and you'll find it in such things as factory machines and floating "maglev" (magnetic levitation) railroads.

Another interesting design is the brushless DC (BLDC) motor. The stator and rotor effectively swap over, with multiple iron coils static at the center and the permanent magnet rotating around them, and the commutator and brushes are replaced by an electronic circuit. You can read more in our main article on hub motors. Stepper motors, which turn around through precisely controlled angles, are a variation of brushless DC motors

TYPES OF MOTORS1.DC motor- DC shunt motor -separately excited motor -series motor -permanent magnet direct current -compound motor2.AC motor induction motor -synchronous motor

OTHERS MOTORS-stepper motor -Brushes DC motor-hysteresis motor -reluctances motor -universal motor

DC motor is a electrical machine which converts dc electrical energy into mechanical energy. When power supply is connected to the motor then it is divided into two parts field winding and armature winding. Field winding makes electromagnet in this magnetic field current carrying armature winding experience the mechanical force and start rotating due to this shaft is also rotating.

DC MOTOR

Flux control method:- In this method when flux per pole increases the speed of dc motor decreases and if flux per pole decreases speed increases.Armature control method:-when overall resistance of armature circuit increases.The voltage drop across armature increases. Therefore, back e.g. decreases because Eb=V-Ia.RaHence , speed get decreased.

SPEED CONTROL OF DC MOTOR

Types of generation of control DC MOTOR 1st generation :- resistor control method set.2nd generation :-MG set (motor generator set).3rd generation :-Thermonic valves.4th generation :-Semiconductor devices i.e., thyristor.

An electric drive is defined as a form of machine equipment designed to convert electrical energy into mechanical energy and provide electrical control of this process.

The basic elements of an electric drive are the electric motor, the transmission, and the electrical control system. Electric drives often include conversion equipment (frequency changers , rectifier units , motor-generator sets etc.)to attain smoother and more versatile control and make the motor operate on specific speed-torque characteristicsINTRODUCTION TO ELECTRIC DRIVES

Capital costs vary with rating of the drive. Larger drives with more performance features will cost more. By way of comparison, A.C. drive controllers cost more than D.C. drive controllers, but A.C. motors cost less and have lower maintenance costs than brushed D.C. motors. While D.C. drives have a wide speed range, they may require thyristors with higher ratings due to the higher currents associated with low speed operation. Efficiency is the ratio of output power to input power.

Low efficiency has two disadvantages: (1) costly wasted energy and (2) excessive heating of the drives components and the motor. D.C. drives typically have high efficiencies; however, at low speeds, they have a low power factor. D.C. drives have a power-to-weight ratio advantage over Ward-Leonard electric drives but less so compared to A.C. drives

Process control and energy conservation are the two primary reasons for using an adjustable speed drive. Historically, adjustable speed drives were developed for process control, but energy conservation has emerged as an equally important objective.Adjusting speed as a means of controlling a processThe following are process control benefits that might be provided by an adjustable speed drive:Smoother operationAcceleration controlDifferent operating speed for each process recipeCompensate for changing process variablesAllow slow operation for setup purposesAdjust the rate of productionAllow accurate positioningControl torque or tensionAllow catching of spinning load (e.g., column of water) after outage.

REASONS FOR USING ADJUSTABLE SPEED DRIVES

An adjustable speed drive can often provide smoother operation compared to an alternative fixed speed mode of operation. For example, in a sewage lift station sewage usually flows through sewer pipes under the force of gravity to a wet well location. From there it is pumped up to a treatment process. When fixed speed pumps are used, the pumps are set to start when the level of the liquid in the wet well reaches some high point and stop when the level has been reduced to a low point. Cycling the pumps on and off results in frequent high surges of electric current to start the motors that results in electromagnetic and thermal stresses in the motors and power control equipment, the pumps and pipes are subjected to mechanical and hydraulic stresses, and the sewage treatment process is forced to accommodate surges in the flow of sewage through the process. When adjustable speed drives are used, the pumps operate continuously at a speed that increases as the wet well level increases. This matches the outflow to the average inflow and provides a much smoother operation of the process

There are three general categories of electric drives: DC motor drives, eddy current drives and AC motor drives. Each of these general types can be further divided into numerous variations. Electric drives generally include both an electric motor and a speed control unit or system. The term drive is often applied to the controller without the motor. In the early days of electric drive technology, electromechanical control systems were used. Later, electronic controllers were designed using various types of vacuum tubes. As suitable solid state electronic components became available, new controller designs incorporated the latest electronic technologyTYPES OF DRIVE

DC drives are DC motor speed control systems. Since the speed of a DC motor is directly proportional to armature voltage and inversely proportional to motor flux (which is a function of field current), either armature voltage or field current can be used to control speed. Several types of DC motors are described in the electric motor article. The electric motor article also describes electronic speed controls used with various types of DC motors.

DC DRIVE

An eddy current drive consists of a fixed speed motor and an eddy current clutch. The clutch contains a fixed speed rotor and an adjustable speed rotor separated by a small air gap. A direct current in a field coil produces a magnetic field that determines the torque transmitted from the input rotor to the output rotor. The controller provides closed loop speed regulation by varying clutch current, only allowing the clutch to transmit enough torque to operate at the desired speed. Speed feedback is typically provided via an integral AC tachometer.

EDDY CURRENT DRIVE

Advantage of 32 DC drive family

Heat sink over temperature warning.DC motor temperature sensing with over temperature protectionAC line fuses and DC link fuse on regenerative units.Fully rated DC contactor (includes Db pole on most sizes)Chassis type construction IOC(instantaneous over current)protectionPhase loss/phase sequence protectionField current loss protectionField economyLow AC line v/g and frequency protection16 event fault FIFOAll drive information accessible by remote computer over a RS485 multi drop link. Advantage of 32 DC drive family

Avtron introduction

Since 1953, Avtron has been a leader in designing and manufacturing Electrical Control and Test Equipment. Their Aerospace, Industrial Automation, and Load Bank facilities occupy four buildings in Northeast Ohio, to accommodate manufacturing, sales, and engineering resources. Twenty-five percent of Avtron's employees are graduate engineers in electrical, computer, and mechanical fields. . Anywhere in the world and at any time, installation, start-up, and support services are available on all Avtron products.

Avtron drive system

Inner look of drive parts Drive parts Drive switches

Block diagram of single line diagram of 5HP

BILL OF MATERIAL OF 5HP

Purpose:

Speed and/or Position Feedback to Electrical Drive SystemsLength, Speed, and/or Position Feedback to Process Instrumentation and ControlsThere are many applications for rotary pulse generators (also known as incremental encoders, tachs, tachometers) throughout industry. Avtron manufactures a wide range of electrical and mechanical configurations to satisfy the installation requirements of your application. These units typically mount to the non-drive end of AC and DC motors for speed feedback applications and in some cases directly to roll shafts for instrumentation.

Drive interfacing parts

Drives components

ARMATURE CONVERTOR CIRCUIT

Advanced Communication:

IEEE 802.3 (ETHERNET) LAN with Modbus TCP protocolIEEE 802.3 (ETHERNET) LAN with Allen-Bradley ETHERNET/IP protocolIEEE 802.3 (ETHERNET) LAN with GE EGD protocolRS 485 Serial Link with Allen-Bradley DF1 protocol

Applications:

Avtron produces "Mill-Duty", "Heavy, Mill-Duty" and "Severe Duty" encoders to handle rugged environments encountered in the following industries:Pulp and PaperMetalsRubberPlastic FilmMaterial HandlingMiningFiberglasRoofingConvertingTest EquipmentTextilesNon-WovensCement Kilns

Here we familiarize with industrial application of motor and drives. Its a very precious moment of our life where we seen a different kinds component in large parameters . We try to analyze our knowledge in accordance with their requirements.

CONCLUSION

THANK YOU

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