1ST ASIAN MINING CONGRESS

16-18 January, 2006, Kolkata, India

The Mining Geological and Metallurgical Institute of India (MGMI), Centenary

FREQUENCY CONTROL SYSTEM FOR IMPROVING EFFICIENCY

OF CONVENTIONAL COAL MINE HAULER EFFICIENCY
Srinivasulu Tadisetty and R.N.Gupta*

ABSTRACT

The conventional coal mine hauler employs resistance controls for controlling the speed of three phase
slip ring induction motor. This is not an intelligent and efficient controller for precisely controlling
speed to regulate power requirement as it is non linear in its functioning. The conventional hauler also
needs regular maintenance and consumes more power. Therefore, the productivity and safety of
conventional hauler is not appreciable. The authors successfully developed the variable frequency control
system and interfaced it to the conventional hauler for improving efficiency and safety, This paper
discusses the role of variable frequency system in improving the efficiency of conventional hauler.

INTRODUCTION mine power systems (Stefanko, 1983). The improved

For successful planning of a new mine or, when
reorganizing and/or modernizing existing mines for
increased production and productivity, none is of greater
importance to mine planners than the selection of a
suitable hoisting system and hoisting equipment in order
that the hoisting plant operates, under given conditions,
at maximum efficiency with minimum capital and operating
costs. Owing to rapid technological developments and
innovations that are being made by giant mining
machinery manufacturing companies throughout the
world, the hoist drives, speed control systems, safety
control systems, and condition monitoring systems have
become more and more sophisticated and complex.
Since, mechanization in coal mines began with haulage,
the history of mine haulage is, basically, the history of
coal mine mechanization and especially, the evolution of
haulage is a major factor in overall mine efficiency.
As per the investigations of the Electrical Power
Research Institute (EPRI), USA over 60% of industrial
motors are operating under 60% of their rated load
capacity. Idling, cyclic, lightly loaded or oversized motors
consume more power than required even when they are
not working. These motors are wasting energy, generating
excessive utility costs and unnecessary motor wear. The
speed of slip-ring induction motor at a given torque can
be controlled by inserting resistance in the rotor circuits
which vary the slip, the speed depending on the amount
of additional resistance per phase. The resistances are
usually connected in delta. The motor, however, loses its
shunt characteristics with increase of resistance and the
speed becomes largely dependent on load. The
conventional resistance control method has many

* National Institute of Rock Mechanics, Kolar Gold Fields-563 117, Email : tadisetty_s@yahoo.co.in
142 Frequency Control System for Improving Efficiency of Conventional Coal Mine Hauler Efficiency
drawbacks. It is large in size, control is rough leading to
coupling problems and starting difficulty, considerable
energy is wasted as heat. The safety and productivity of
conventional hauler further deteriorates because of the
poor performance of resistance control system (Ramulu,
1996).
A variable frequency controller is an electronic
controller that adjusts the speed of electric motor by
modulating the power being delivered. Variable frequency
control (VFC) system provides continues control,
matching motor speed to the specific demands of the work
being performed. The VFC system gradually ramps up a
motor to operating speed. This lessens mechanical and
electrical stress on the motor and can reduce maintenance
and repair costs and extend motor life. As a result, energy
saving from the VFC system can be significant. The
authors successfully developed the frequency control
system and interfaced to the conventional coal mine hauler
in one of the Indian mines for improving efficiency and
safety.
FREQUENCY CONTROLS
The frequency controllers are made in four types:
variable-voltage inverter (VVI), pulse-width modulated
(PWM), current-source inverter (CSI), and load
commutated inverters (LCI). Each has specific
characteristics and advantages.
Variable-voltage inverter (VVI)
Although this design was common in the 1970s and
early ‘80s, it is now generally limited to special applications
such as high-speed controls/drives that deliver 400 to 3,
000 Hz. The VVI design receives ac power, rectifies and
controls it, and delivers variable-voltage dc to the power
amplifier (inverter). The power amplifier inverts the
variable-voltage dc to variable-frequency, variable-voltage.
It can be built with power transistors or SCRs. The output
voltage from a VVI unit is frequently called a six-step wave
form. The VVI was one of the first solid-state controllers
to gain general acceptance.
Pulse-width modulated (PWM):
PWM is a digitally encoding analog signal levels.
Through the use of high-resolution counters, the duty cycle
of a square wave is modulated to encode a specific analog
signal level. The PWM signal is still digital because, at
any given instant of time, the full DC supply is either fully
on or fully off. The voltage or current source is supplied to
the analog load by means of a repeating series of on and
off pulses. The on time is the time during which the DC
supply is applied to the load, and the off time is the periods
during which that supply is switched off. Given a sufficient
bandwidth, any analog value can be encoded with PWM.
Pulse Width Modulated (PWM) controller used with an
ac motor is the economical way of producing a motor
system with variable speed. With the advent of low cost
power semiconductors capable of high speed switching,
the variable voltage and frequency control required by
the ac motors is easily achieved using the technique of
Pulse Width Modulation. PWM units use several types of
power transistors (including insulated gate bipolar
transistors (IGBTs), and gate-turn off SCRs (GTOs). The
PWM power circuit requires a more complex regulator
than does the VVI design. However, the increasing use
of microprocessors has nearly eliminated significant
economic differences. The PWM power circuit is
commonly used with three basic types of regulators. It is
these regulators that largely determine the control
capabilities, including response, speed regulation due to
transient load changes, and low-speed torque capabilities.
The brief descriptions of three regulators are as follows:
Volts/Hertz A volt per hertz control describes a
relationship that is fundamental to the operation of motors
using adjustable frequency control. An ac induction motor
produces torque by virtue of the flux in its rotating field.
Keeping the flux constant will enable the motor to produce
full load torque. Below base speed, this is accomplished
by maintaining a constant voltage to frequency ratio
applied to the motor when changing frequency for speed
control. This design generally offers the basic
adjustments-including set speed, torque limit, V/Hz,
voltage boost at low speeds, minimum and maximum
speeds, acceleration and deceleration rates, and other
similar adjustments, which meet the requirements for most
applications. This controller is being used for developing
the VFC system in the present context.
Basic vector - Introduced in the mid-80‘s, this
regulator was a significant advancement over the Volts/
Srinivasulu Tadisetty and R.N.Gupta 143

Hz design. Such units use an approximation method to resistance is a measure of the condition of the motor
control the stator and rotor flux angles to optimize motor winding insulation. If the resistance is over (about) 300
operation. Some vector controls were expected to have 000 ohms, then the motor is probably OK for the VFC
open-loop speed regulation (no speed feedback signal retrofit. If the resistance is less than 300 000 ohms then
from the motor). Regardless of this fact, the basic vector the motor should be “dipped and baked” to renew the
does offer improved performance, which in some cases winding insulation. Moreover, if the motor has been idle
may be suitable for simple coordinated systems. for a long time-several weeks or more-then the motor
should be run long enough to bring it up to operating
Vector - More recently, in the mid 90s, much
temperature and kept there for an hour or more before
improved vector regulators were introduced. These have
conducting the Meggar test.
more advanced microprocessors and DSPs that
significantly enhance controller operation, including CONVENTIONAL COAL MINE HAULER
response and position regulation capabilities. One reason
Figure 1 shows the block diagram of the conventional
for the vector’s capability to perform so well is its ability to
hauler. The incoming ac power is received by slipring
“see” the counter EMF produced by the motor, then the
induction motor through F&R, drum controller, resistance
circuitry adjusts the start of each PWM pulse train and
and brush gear units. The incoming power is controlled
the specific duration of each pulse.
by resistance through drum controller and F&R units. The
Current-source inverter (CSI) slipring induction motor speed is reduced by speed
reduction gear box to 30:1. The speed of motor is 750
Usually applied to 50hp and larger motors, CSI units
rpm in present context. The speed is reduced to 25 rpm.
are well suited for powering pumps and fans as an energy-
The coal tubs are connected to the rope and are interfaced
saving alternative to throttling for flow control. The CSI
to the reduction gear box. The speed of the slipring
design offers economy over both the VVI and PWM units
induction motor is controlled by adding/subtracting
for pump, fan and similar applications. The CSI inherently
resistances in series through drum controller unit.
offers regenerative capabilities. With an overhauling load,
However, the non-linear resistance controller has
the controller feeds power back into the ac power system.
limitations like burning of resistance coils, improper
contacts, brushes of the brush gear unit damaged,
Load-commutated inverter (LCI)
derailment of coal tubs and so on. Therefore, the efficiency
Designed for controlling synchronous motors rated of the conventional hauler is not appreciable.
in hundreds or thousands of horsepower, these units use
the leading power-factor capabilities of synchronous
motors to commutate the power SCRs off. These
inverters, some rated up to 6000 Vac, control large blowers
and induced draft fans in power plants. Due to the higher
cost of synchronous motors over conventional induction
motors, LCI systems become economical in the 400-600
hp range and larger (Srinivasulu and Gupta, 2004).

RETROFITTING VFC
In general, existing motors in good condition can be
retrofitted with VFCs. There are, however, some
limitations. The motor windings must be in good condition.
To determine if a motor is appropriate for a VFC retrofit, a Figure 1 Major Blocks of Conventional Coal Mine Hauler
Meggar test is used. A Meggar test measures the
resistance between the motor windings and ground. This
144 Frequency Control System for Improving Efficiency of Conventional Coal Mine Hauler Efficiency
VFC BASED COAL MINE HAULER
Figure 2(a) Block diagram of Microprocessor based VFC system
Figure 2(b) Block diagram of VFC system based Coal Mine Hauler
The microprocessor based VFC system has been
developed with various modules. However, the system
was interfaced to the various sub/peripheral systems
(Figure 2(a)). The VFC system converts incoming AC
power from the mains into pulsating DC voltage by the
input diode bridge. This is supplied to the bus filter
capacitors through a charging circuit, which limits inrush
current to the capacitors during power-up. The pulsating
DC voltage is filtered by the bus capacitors, thereby
reducing the ripple level. The filtered DC voltage enters
the IGBT section of the system, composed of six output
intelligent insulated gate bi-polar transistors (IGBTs),
which make up the three output legs of the system. Each
leg has one intelligent IGBT connected to the positive
bus voltage and one connected to the negative bus
voltage. Alternatively, switching on each leg, the intelligent
IGBT produces an alternating voltage on each of the
corresponding motor windings. By switching each output
intelligent IGBT at a very high frequency (known as the
carrier frequency) for varying time intervals, the system
is able to produce a smooth, three phase, sinusoidal output
current wave which optimizes motor performance.
Therefore, the operations are efficient and smooth.
Further, the system has regeneration/dynamic breaking
facility for hauling high inertia loads on inclined roadway
as in coal mines. It has robust operators keyboard with
minimum keys and it may be operated by an unskilled
mine worker. The programming of various parameters
and configurations are protected with dynamic software
lock. Thus, it does not allow unauthorized operations.
Besides, it has many security features for protecting from
unauthorized operations.
The system was incorporated with changeovers for
interfacing to conventional hauler in-parallel to
conventional controls. The conventional controls and
slipring induction motor was interfaced through this
changeovers (Figure 2(a)). The VFC based coal mine
hauler (Figure 2(b)) has fewer modules than the
conventional coal mine hauler (Figure 1). The new system
eliminated problematic electro-mechanical modules. The
system allows uninterrupted operations due to
changeovers. It can be easily changed to new or old
configuration as and when required. The VFC system can
work with low cost squirrel cage induction motor. As a
result, the capital investment can be reduced significantly
with appropriate planning. The VFC system can reduce
wear and tear, thereby reducing maintenance costs and
prolongs the life of the motor.
ENERGY CONSERVATION
Figure 3 Comparison of energy conservation
Figures3 shows the energy conservation comparison
between new VFC and conventional hauler. The power
consumed by the VFC system at 125 rpm is much less
compared to convential hauler as VFC system consumes
10 amps whereas conventional hauler consumes 40
amps. Similarly, the VFC system consumes 25 and 35
Amp at 375 and 500 rpm, respectively. But, the
conventional system consumes 45 and 48 Amp at 375
Srinivasulu Tadisetty and R.N.Gupta
and 500 rpm, respectively. At full speed of 750 rpm, both
the systems consumes same power. As per the detailed
field investigations, the VFC system consumed less
power, when operated below rated speed (Figure 3). But,
the conventional system consumed more power during
starting and below rated speed. Therefore, the VFC
system has linear relation and conventional system has
non-linear relation with power conservation. Thus, the VFC
system saves significant amount of energy. It is an energy
efficient system.
CONCLUSIONS
The VFC system was successfully developed and
interfaced to the conventional coal mine hauler. The
innovative VFC system has eliminated significant number
of problematic electromechanical modules of conventional
system and has reduced maintenance. Besides, the
power saving was significant. Further, it improved safety
of operations and improved efficiency and safety of
conventional coal mine hauler. Therefore, the innovative
system would play a vital role in future energy crisis. The
VFC system in present context is fully applicable to coal
mine haulers. However, it can be interfaced to other
145
applications like fans, pumps, shovels and so on with
appropriate modifications.
ACKNOWLEDGEMENTS
The authors are indebted to Singareni Collieries
Company Limited and Department of Coal, Government
of India for supporting field experimentation and providing
necessary funds respectively. The views expressed in this
paper are those of the authors and not necessarily of the
organization they represent.
REFERENCES
1. Robert Stefanko, Coal Mining Technology, Society
of Mining Engineers, New York, USA, 1993
2. M.A. Ramulu, Mine Hoisting, Oxford IBH Publishing
Co. Pvt. Ltd, New Delhi, 1996
3. Srinivasulu Tadisetty and R.N.Gupta, “Development
and application of New Innovative System for
reducing power consumption and improving efficiency
of conventional coal mine hauler”, Proceedings of
International conference on New Equipment-New
Technology, Management, & Safety in mineral based
industries, 11-12 May 2004, Bhubaneswar