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VDZ-Onlinecourse 6 5 en
VDZ-Onlinecourse 6 5 en
CoursehLBh6.5hhDrivehTechnology
VDZhOnlinehCourses // Cement
Imprint
info@elearning-vdz.de
www.elearning-vdz.de/en
Solutions............................................................................................................................... 21
Glossary ............................................................................................................................... 23
Index..................................................................................................................................... 25
VDZ gGmbH
Research Institute of the Cement Industry
1 Introduction
Modern drive technology is one of the basic elements of almost all production processes.
This is particularly true of the cement production process, where a number of individual
processes (e.g. comminution, burning and comminution) are carried out in succession.
These individual steps are generally carried out in different locations, so conveying equip-
ment is used to connect them. All these components require electric drives.
This course will give an overview of the basic structure and operating principle of drives
and will also discuss the most important types of drive.
Course Summary
VDZ gGmbH
Research Institute of the Cement Industry
2 Basics of Electric Drives
stator windings
rotor windings
brushes
VDZ gGmbH
Research Institute of the Cement Industry
2.2 Three-Phase High-Voltage Motors
R=R
MN
R=
2
R
2R
=
R
3R
2
=
200 %
R
R
2
=
=
R2
R
5
7
R
=
9 R2
2
R2
100 %
n
0%
n
25 % 50 % 75 % 100 % N 3
Figure 2.1-3: Characteristic Speed/Torque Curves at Different Levels of Resistance in the Rotor Circuit
.
The torque curve is plotted against rotational speed, based in each case on rated values. At
the rated speed (i.e. nnN = 100%), the torque falls to zero. The figure shows a group of
curves produced by changing the external resistance R. In this instance R2 is the resistance
of the rotor winding. When the external resistance is increased the maximum achievable
torque (breakdown torque) shifts in the direction of lower rotational speed. For example,
at R = R2 (i.e. the external resistance is equal to the resistance of the rotor winding) the
maximum torque occurs at more than 75 % of the rated speed. If the external resistance is
doubled to R = 2R2, the maximum torque occurs at less than 75% of the rated speed.
VDZ gGmbH
Research Institute of the Cement Industry
2 Basics of Electric Drives
ery allow the drive motor to be started up directly, a three-phase squirrel-cage motor may
also be used in a power range from 200 kW to 800 kW.
VDZ gGmbH
Research Institute of the Cement Industry
converter drive systems
converter -
DC drive
DC
converter -
three-phase drive
5
3-phase - slipring motor with subsynchronous
controllable three-phase drives
converter cascade
fans
classifiers
metering equipment
high-pressure roller mills
grate coolers
rotary kilns
The largest single drive is a mill motor with a power rating of approx. 3,500 kW.
In larger plants single drives with a power up to 6,000 kW are used.
The majority (approx. 98 %) are low-voltage motors with individual power ratings of
up to approx. 200 kW.
VDZ gGmbH
Research Institute of the Cement Industry
3 Fields of Application of Electric Drives
High-voltage motors are used for preferance for drives over 200 kW (approx. 2
%). This power boundary may rise to 500 kW depending on the design of the cement
works power network.
An overview with regard to the different engine types is given in Fig. 3.0-1.
Figure 3.0-1: Different Kinds of Motors in a Cement Plant . (Source: Siemens AG (Editing by VDZ))
VDZ gGmbH
Research Institute of the Cement Industry
3.1 Tube Mill Drive
simple adjustment of the resistance to the drive by changing the electrolyte concentra-
tion
low wear
7
maintenance-free
6 kV 50 Hz
A A
3
m1 5 m1
6
7
M
1 disconnecting switch
2 power switch
3 current transformer for current measurement
4 current transformer for bimetallic relay
5 mill motor
6 starter
7 adjusting motor for the starter
Two separate starters are used in dual drives, as shown in Fig. 3.1-2. They are mechanically
and electrically linked for simultaneous stepping of the starting resistors. Liquid starters
are connected by pipelines so that the concentration of the electrolyte remains the same
in both starters. This avoids different starting currents and therefore also different starting
torques.
VDZ gGmbH
Research Institute of the Cement Industry
3 Fields of Application of Electric Drives
An innovative drive concept, especially for larger mills, is the so-called MultiDrive. The
Mul-tiDrive (s. Fig. 3.2-2) consists of two to six identical drive modules which turn the
grinding table via a gear ring. The gear ring is located below the grinding table.
Figure 3.2-2: Siemens/Flender MultiDrive concept for the grinding table. (Source: Siemens AG)
As shown by the torque curve (Fig. 3.2-3), the breakaway torque of the vertical roller mill
lies below the nominal torque. However, the load torque increases during start-up (with
uneven material distribution on the grinding table) to up to 150 % of the nominal torque.
The starter is designed accordingly.
Start-Up The bed of material is smoothed using an auxiliary drive that has a rotational speed of
VDZ gGmbH
Research Institute of the Cement Industry
3.3 High-Pressure Roller Mill Drive
40
20
0 n
10 20 30 40 50 60 70 80 90 100 % n
s
1 curve of a short-circuited rotor
2 the size of the load torque is dependent on the settings of the roller hydraulics
approx. 10 % of the main drive so that the vertical roller mill can be started up with
9
the grinding table completely covered. This auxiliary drive drives the other projecting
end of the main motor shaft through an auxiliary gear unit. The grinding table is then
driven through the angular gear unit. An overrunning clutch between the auxiliary gear
unit and the main motor as well as an electric interlocking system prevent the danger of
the auxiliary drive being driven by the main motor.
Large fluctuations in current and therefore power (curve 3 in Fig. 3.2-3), caused by the
composition of the bed of material, occur during normal grinding operation.
VDZ gGmbH
Research Institute of the Cement Industry
3 Fields of Application of Electric Drives
10
the kiln. If there is one-sided build-up then these situations can cause periodic changes in
torque superimposed on the constant load torque.
The fluctuations in torque that are to be expected are taken into consideration in the drive
design by allowing for a reserve capacity of 35 to 50 % of the power requirement. The
speed adjustment range of the rotary kiln is 10 to 100 % of the nominal speed. The low
range is required in particular for the heating and start-up processes.
DriveSystems Only the following variable speed drive systems are used:
DC motors
frequency converter drives
hydraulic drives
PowerTransmission The drive power can be transmitted from the motor to the rotary kiln in the following ways:
single motor gear unit pinion girth gear
two motors two gear units two pinions girth gear
direct drive of support rollers (Fig. 3.4-1)
Auxiliary Drive The rotary kiln is equipped with an auxiliary drive that permits slow rotation of the kiln
for emergency operation in case of power failure and for repair purposes. This drive is
flange-mounted to the main gear unit and is supplied by an emergency power supply.
Continuous slow rotation makes it possible to avoid any bending of the kiln tube during
power failure.
The hydraulic drive is described in the section on Rotary Kiln Drives, p. 14 .
VDZ gGmbH
Research Institute of the Cement Industry
3.6 Crusher Drives
VDZ gGmbH
Research Institute of the Cement Industry
4 Special Drive Designs
of the rotor and so utilizes the energy stored in the rotating mass. This does, however, have
a detrimental effect on the overall efficiency of the drive.
12
VDZ gGmbH
Research Institute of the Cement Industry
tors that are used to drive unbalanced masses mounted on both protruding shaft ends. The
stroke can be altered by adjusting the unbalanced mass or by changing the speed.
The iron cores of electromagnets operate against spring assemblies. The stroke and there- Electromagnets
fore the flow rate can be altered in a range from 50 to 100 % by adjusting the voltage using
an electronic actuator.
5 Electro-Hydraulic Drives
Hydraulic systems are used when high power density and good thermal dissipation or very
strong forces are needed.
Electro-hydraulic systems (Fig. 5.0-1) are formed of hydraulic and electric compo-
nents; energy is transmitted between the power section and the hydraulic drive by a
liquid under high pressure.
K1
24V
directional
control
valve
y1
power section
M
K1
control section
OV
High power density is one of the main features of hydraulics. This refers to the ratio
of power output from a motor to its weight or size.
PowerDensity
Electric motors, for example, have a considerably lower power density. An electric motor
that has the same power out as a hydraulic motor is many times heavier and larger.
However, signal input and signal processing are carried out using electrical and electronic Advantage:
components. Electric signals can be transmitted reliably and over large distances using SignalTransmission
cables. Mechanical signal transmission (rods, cable pulls) or hydraulic signal transmission
(tubes, pipes) is considerably more complex and more susceptible to failure. For this
reason electro-hydraulic systems are also, for example, being used increasingly in aircraft
or motor vehicles. In automation technology all the signal processing is usually carried
out electrically. Electro-hydraulic systems are therefore better suited for use in automatic
production systems, e.g. cement production plants.
The interface between electric/electronic and hydraulic systems is the electromagnetically Valve Interface
actuated valve. The electromagnet (Fig. 5.0-2) is the core element of the valve. The
action of the electromagnet is based on the fact that a magnetic field is produced by a
VDZ gGmbH
Research Institute of the Cement Industry
5 Electro-Hydraulic Drives
iron magnet
coil core
14
Figure 5.0-2: Electromagnet .
conductor winding (coil) through which current flows. This exerts a force on an iron
rod (core) immersed in this magnetic field. The arrangement of the coil and core can be
designed in such a way that the core can be moved into different positions. This movement
makes it possible to carry out control processes. It is, for example, possible to operate a
directional control valve.
The force of the electromagnet on the core is proportional to the strength of the
current flowing through the coil and the number of windings in the coil.
VDZ gGmbH
Research Institute of the Cement Industry
5.1 Rotary Kiln Drives
rotary kiln
cooler
tank
1. cam disc
2. cam roller
3. piston
4. shaft coupling
5. radial cylinder/hollow shaft
6. guide plate
7. roller bearing on cam roller
7a. roller bearings for radial
cylinders
8. terminal block
9. valve disc
10. front housing
11. rear housing
R = "R" inlet or outlet
L = "R" inlet or outlet
D1, D2, D3 and (D4)* = leak ports
As previously mentioned, the pump module for the kiln drive station consists of three
modules. Two of these are main modules, each consisting of two electrically driven main
pumps. The hydraulic pumps are axial piston pumps with variable displacement. This
adjustment is controlled individually by a proportional valve.
The third module consists of a small electrically driven pump with its own filters. This
pump is used with emergency power for normal rotation of the kiln, but this small pump
can also generate higher pressure than the four main pumps. It is used during start-up.
Maximum speeds of 0.2 revolutions per minute can generally be achieved with this pump.
VDZ gGmbH
Research Institute of the Cement Industry
5 Electro-Hydraulic Drives
If the position is different to the intended position, the magnets of the pilot valve are
activated by the valve electronics, which changes the amount of control oil passing to the
main valve. Its piston position is changed so that correspondingly more or less oil under
pressure enters the piston end or the fixed end of the cylinder.
The valve electronics are integrated into a subordinate control circuit. The stroke time is
generally set by the control room and reaches the controller module via the programmable
control. The card calculates the corresponding speed profile, which is supplied to the
valve electronics as a setpoint. Position data is fed back to the controller module by a
displacement transducer integrated into the cylinder.
Pressure Control
Once the hydraulic system has been started, the maximum value is generally initially set
as the control pressure setpoint and is then reduced or adjusted in steps with each stroke.
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Research Institute of the Cement Industry
The cylinder is equipped with two pressure transducers that, together with a manometer
for displaying the control pressure, are mounted externally in the vicinity of the cylin-
der. One of the pressure transducers measures the pressure on the piston side whilst the
other measures the pressure on the rod side. These pressures are read continuously by
the programmable control. At the end of the stroke the lower value is compared with the
predetermined threshold value. The higher the control pressure should be, the more the
pressure control valve is closed.
17
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Research Institute of the Cement Industry
9 Maintenance and Inspection
8 Environmental Protection
Energy Consumption Operating unnecessary equipment, such as compressors, or running empty conveying
equipment such as bucket elevators or the like has a negative effect on specific power
consumption. Inadequate maintenance and servicing of production systems also leads to
higher energy consumption.
Noise The emissions from drives are largely limited to noise. This is produced in particular
when operating large motors and frequency-controlled drives. Noise can be prevented
or reduced by design measures. Pumps and compressors are enclosed to reduce noise
emissions. Special noise protection measures must be taken at the air intake and discharge
openings that are needed to cool the drives.
Discharge of Oil The environmentally harmful discharge of hydraulic and lubricant oils and their pene-
tration into the ground is prevented by using catchment basins or by structural measures
such as oil-tight sumps.
VDZ gGmbH
Research Institute of the Cement Industry
However, in the case of serious malfunctions, short-term plant downtime may also be
necessary in order to carry out repairs.
inspection of the bearings MaintenanceMeasures
checking of the winding temperature
functional testing of the protective relay and interlock devices
functional testing of bearing temperature monitoring system
inspection and cleaning of the cooling systems
inspection and maintenance of the carbon brushes
inspection and maintenance of slipring elements and collectors
functional testing and maintenance of oil circuits
functional testing and maintenance of cooling water circuits
functional testing of safety switch devices
In addition, special attention must be paid to the operating instructions for the drive in
question.
The following points have a significant effect on the operability and service life of drives: Wear and Corrosion
protection against dust and radiant heat 19
protection against vibration
uninterrupted supply and removal of cooling air
effective overload protection
Question 10.0 A:
1.: Which type of motor is most commonly used?
2.: For which drives is a slipring motor used?
3.: How are electric motors cooled?
4.: Name some factors that contribute to the cost-effectiveness of high-voltage motors.
5.: Which are the drives and power levels for which high-voltage motors are used for
prefence?
6.: Which drive types are suitable for variable-speed drives?
7.: Name the fields of application for variable-speed drives in a cement works.
8.: Why are three-phase slipring motors used to drive tube mills?
9.: What are the advantages of a liquid starter?
10.: What causes strong fluctuations in torque of a vertical roller mill during normal
mill operation?
11.: Why must a roller mill always be started up with an auxiliary drive?
12.: Why is the drive of a high-pressure roller mill equipped with a variable-speed main
drive system?
13.: Why are rotary kiln drives always provided with variable-speed drives?
14.: Why is it necessary to allow for a power reserve capacity of 35 to 50 % of the
nominal power in rotary kiln drives?
15.: What is the purpose of the auxiliary drive of a rotary kiln?
16.: How is the volume flow of a fan adapted to the process requirements?
17.: Name some special drive motor designs.
18.: Name the drive types used for heavy starting.
19.: What are the advantages of the electronic smooth starting device?
VDZ gGmbH
Research Institute of the Cement Industry
10 Questions on Course LB 6.5 Drive Technology
20
VDZ gGmbH
Research Institute of the Cement Industry
Solutions
Solutions to 10.0 A:
1.: Three-phase squirrel-cage motor
2.: For drives that require low-impact starting
3.: Surface-cooling by self-ventilation
4.: low motor losses
low network costs
low network losses
low cable costs
5.: Crusher systems
Raw meal systems
Fans
Compressors
Cement grinding plants
from approximately 200 kW drive power, depending on the cement works power 21
network
VDZ gGmbH
Research Institute of the Cement Industry
10 Questions on Course LB 6.5 Drive Technology
19.: The electronic smooth starting device is provided with a microprocessor control
system that makes it possible to adapt the drive to the working machinery. After
the drive has started up the device is bypassed so that additional energy loss can be
avoided.
20.: When high power density and good heat dissipation or very high forces are re-
quired
21.: High power density, electro-hydraulic system
22.: Isolate
Secure against reconnection
Check that the system is safely isolated from power supply
Earth and short circuit
Cover or shield any adjacent live parts
23.: Production losses, blockages and overloading of transport routes, reduction in the
service life of refractory linings, increase in dust emissions, damage caused by
overheating in gas ducts
24.: Overloading, overheating, blockages, electrical malfunctions, bearing damage, in-
22
terruption of the power supply
25.: Inspection of the bearings, checking of the winding temperature, functional test-
ing of the bearing temperature monitoring system, inspection and cleaning of the
cooling systems, inspection and maintenance of the carbon brushes, etc.
Question see p. 19
VDZ gGmbH
Research Institute of the Cement Industry
Glossary
DC motor
Electric motor operated with direct current.
electromagnet
A magnetic field is produced by a conductor winding (coil) through which current flows; this magnetic field
exerts a force on an iron core immersed in it
high-voltage motor
Electric motor that is operated at a higher voltage; the voltage is normally 6 kV or 10 kV, in older plants it may
also, for example, be 2.4 kV, 3 kV or 5 kV
hydraulic motor
Drive motor that converts the kinetic energy of a liquid into a rotational movement
IEC (International Electrotechnical Commission)
International Electrotechnical Commission; international standardization committee in the field of electrical en-
gineering and electronics (similar to ISO)
IP44
IP protection class 44 = protection against foreign bodies > 1mm in diameter (first 4) AND protected against
spray water (second 4) 23
IP54
IP protection class 54 = complete shock-hazard protection, protection against damaging internal dust deposits
(first number 5) AND protected against spray water (second number 4)
kW
short for kilowatt (= 1,000 watts); measure of electric power; W = current amperage (A) voltage (V); 1 W = 1
joule per second
liquid starter
Starter in which the resistance is formed by a liquid (salt solution)
low-voltage motor
Electric motor that is operated using a low-voltage power supply network (e.g. 400 V or 500 V)
power density
Ratio of power output from a motor to its weight or size
proportional
mathematical term for consistent change (e.g. doubling, tripling) of a variable
resistor starter
Starter with incrementally adjustable fixed resistors
rotor winding
Winding on the moving part (= the rotor) of an electric motor
slipring
The sliprings connect the rotor windings of the slipring motor to a starting resistor; the sliprings make it possible
for the current to flow from a stationary part (e.g. starting resistor) to the rotating part (rotor)
slipring motor
Three-phase motor in which the rotor winding is connected to an external starting resistor by sliprings
squirrel-cage motor
Three-phase motor in which the rotor winding is formed by short-circuit bars (cage)
star-delta circuit
A system for switching the three windings of a three-phase machine between star circuit and delta circuit.
In the star circuit the line-to-line voltage (voltage between 2 phase conductors) is 1.73 times as high as the phase
voltage (voltage between the phase conductor and the neutral conductor); the conductor current is equal to the
phase current.
In the delta circuit the conductor current is 1.73 times as high as the phase current; the conductor voltage is the
same as the phase voltage
starting current
Current drawn by an electric motor when switched on (i.e. in the start-up phase)
starting torque
Torque of an electric motor when switched on (i.e. in the start-up phase)
VDZ gGmbH
Research Institute of the Cement Industry
Glossary
stator
Stationary part of an electric motor;
three-phase motor
Electric motor that is operated using a three-phase power network (= three-phase network); a distinction is made
between the level of operating voltage (three-phase low-voltage motor or three-phase high-voltage motor) and
the type of rotor winding (three-phase squirrel-cage motor or three-phase slipring motor)
24
VDZ gGmbH
Research Institute of the Cement Industry
Index
D
DC motor 4, 10, 11
E
electromagnet 13
H
high-voltage motor 6
hydraulic motor 10, 13
I
IEC 1
IP44 1
IP54 1
K 25
kW 5
L
liquid starter 6
low-voltage motor 5
P
power density 13
proportional 14
R
resistor starter 1
rotor winding 1
S
slipring 1
slipring motor 4, 6, 10
squirrel-cage motor 4, 6, 10
star-delta circuit 12
starting current 1
starting torque 1
stator 1
T
three-phase motor 5
VDZ gGmbH
Research Institute of the Cement Industry