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© ABB Group April 2009 | Slide 1 ABB high performance machines drives for lifts Technical presentation (short version)
© ABB Group April 26, 2015 | Slide 2 ABB high performance machines drives for lifts Technical presentation - Contents Product offering for lifts Hardware, types and ratings Software Example lift system configurations Benefits Lift control program Basic functionality References
© ABB Group April 26, 2015 | Slide 3 Product offering for lifts Hardware High performance machine drive ACSM1 Full power size portfolio available 0.75 to 110 kW, supply voltage 400 V In-built braking chopper as standard Flexibility with different external options Mains filter (EMC) Mains chokes – AC and DC Braking resistor Versatile control interface Digital I/O: 6xDI, 3xDI/O, 1xRO Analogue I/O: 2xAI, 2xAO I/O extension modules Complete range of feedback interfaces Incremental, SinCos, resolver, TTL/HTL Assistant control panel Memory unit for easy drive management
© ABB Group April 26, 2015 | Slide 4 Product offering for lifts Hardware Integrated Safe Torque-Off function (STO) SIL3, certified by TÜV Replacement of one motor contactor Low voltage support for rescue operation 1-phase 230 VAC UPS DC battery from 48 V External DC/DC power supply JPO-01 * * not yet released Regenerative supply unit Full braking energy back to network Group lifts with common-DC Very low harmonic content
© ABB Group April 26, 2015 | Slide 5 Frame sizeABCDE Nominal current Maximum current 2.5…7.0A 5.3…14.7A 9.5…16A 16.6…28A 24…46A 42…80A 60…90A 105…150A 110…210A 165…326A Typical motor power 0.75…3 kW4…7.5 kW11…22 kW*30…45 kW*55…110 kW Braking chopper Braking resistor Mains choke Mains filter (EMC) Product offering for lifts Types and ratings With a mains choke Standard Option, external * Type codes and variants ACSM1-04AL - air cooled ACSM1-04CL - cold plate
© ABB Group April 26, 2015 | Slide 6 Lift system configuration (principled) Example 1
© ABB Group April 26, 2015 | Slide 7 Lift system configuration (principled) Example 2 One motor contactor replaced with STO
© ABB Group April 26, 2015 | Slide 8 Product offering for lifts Software DTC motor control Open and closed loop Lift control program (+N4000) Lift technology library (+N6000) Lift specific signals and parameters Lift terminology and units Control functionality for passanger and goods lifts Ready-made, fully parameterizable Rescue operation Advanced customization with DriveSPC Lift control program Firmware Manual
© ABB Group April 26, 2015 | Slide 9 Benefits Excellent control performance with DTC Open and close loop controls Assures high riding comfort and leveling accuracy in lift applications Geared and gearless solutions Both induction and synchronous motor support with DTC One drive can be used with various motor types Flexible and scalable control interface High amount of I/O as standard Wide range of feedback interfaces Plug-in control options
© ABB Group April 26, 2015 | Slide 10 Benefits Dedicated lift control program Ready made, fully parameterizable and easy to use lift control program Easy and fast start-up with control panel or DriveStudio PC tool Customization with DriveSPC function block programming tool Replacement of one motor contactor with STO Low voltage support for rescue operation 1-phase 230 VAC UPS DC battery from 48 V
© ABB Group April 26, 2015 | Slide 11 Lift control program Basic functionality Drive control logic Mechanical brake control Rescue operation Speed reference selections Speed profile Smart slowdown Supervision and protection functions Torque compensation
© ABB Group April 26, 2015 | Slide 12 Lift control program Drive control logic Basic start/stop logic with two digital inputs Typically two start commands: 1) UP and 2) DOWN Alternatively: 1) START and 2) DIRECTION (UP/DOWN) Start/stop interlocking Provides an interlocking to stop the drive or disable the start without generating any fault or warning End limit logic Generate emergency stop (class 1 - controlled) command when the final limit switch is activated in the respective motor direction Inspection mode operation Dedicated mode used for maintenance operation Inspection speed reference and acc/dec times
© ABB Group April 26, 2015 | Slide 13 Lift control program Mechanical brake control Application software inside the drive control board (JCON) is controlling the mechanical brake via relay output Lift control includes additional functionality for basic brake control Torque proving – electrical check Brake slip detection - mechanical check Fault diagnostics “Gong sound remover” by limiting stopping torque in PM motors due to rapid change in di/dt Brake open torque selection Pre-defined value External AI signal, e.g. weight Can be disabled, if the lift control system takes care of brake control
© ABB Group April 26, 2015 | Slide 14 Lift control program Rescue operation Lift car has to run to the nearest floor in case of power failure situation Precondition: 1-phase UPS-supply or DC-battery available When the start command is given by the lift controller, the drive checks the load in the downward and upward directions and then based on the lighter load, automatically starts to corresponding direction Alternatively the lift controller decides the starting direction Separate speed reference and acceleration/deceleration times Jerk times (shape times) disabled
© ABB Group April 26, 2015 | Slide 15 Lift control program Automatic fault reset Typically needed in applications, where maintenance staff is not directly available for performing fault reset Resets automatically pre-defined drive faults Easy configuration by the user Both application and firmware faults Number of trials and trial time (period) can be configured Delay time for starting auto reset after fault is adjustable Trial time Time Automatic Reset (3 trials) Delay Fault
© ABB Group April 26, 2015 | Slide 16 Lift control program Speed profile Main task to attain high riding comfort and leveling accuracy Guarantee the smooth movement of the lift car High control performance with DTC 7 jerk settings can be selected for different lift operation sequences 4 different acceleration/deceleration times
© ABB Group April 26, 2015 | Slide 17 Lift control program Speed reference selection Easy configuration with three selection signals (DIs) Totally 8 different speeds Releveling speed Leveling speed Nominal speed Inspection speed Medium speed Speed 1, 2 and 3 Off-delay feature for holding the speed reference Adjustable delay time and speed limit Separate speed selection commands for evacuation and inspection modes
© ABB Group April 26, 2015 | Slide 18 Lift control program Smart slowdown for optimizing the leveling Needed, if the normal running speed is not reached between the floors Typical case is a short floor distance Reduces the leveling run and thereby optimizes the travel time of the lift Lift shifts from the nominal speed to the leveling speed only when the leveling distance is reached Two modes Estimated Integral of the estimated speed Encoder Actual position
© ABB Group April 26, 2015 | Slide 19 Lift control program Supervision and protection functions Speed match supervision Monitors the motor actual speed with respect to the speed reference and checks that the actual speed follows the speed reference with a configurable speed deviation limits Inverter overload supervision Monitors the inverter current, torque and power and checks that the drive is operating within the inverter limits Motor stall protection Monitors the motor torque at lower speeds and checks that the motor torque is within the configurable limits Action and diagnostics Drive trips and an alarm is given
© ABB Group April 26, 2015 | Slide 20 Lift control program Torque compensation Method to calculate needed torque due to load and losses beforehand and hereby to help speed regulator for better control accuracy and performance Functionality Static friction compensation Dynamic friction compensation Inertia compensation, i.e. acceleration compensation Final torque compensation ∑ STATIC FRICTION TORQUE DYNAMIC FRICTION TORQUE ACC COMPENSATION TORQUE FINAL TORQUE COMPENSATION
© ABB Group April 26, 2015 | Slide 21 References Motala Hissar AB Motala Hissar AB is a Swedish lift manufacturer, founded in 1972 Develops and manufactures low speed lifts especially to improve accessibility for people with impaired mobility More than 10,000 units have been delivered and installed all over the world More than 60% of the lifts are exported Motala Hissar AB is part of KONE, one of the worlds leading elevator and escalator companies
© ABB Group April 26, 2015 | Slide 22 References Motala Hissar AB Lifting application solution for passenger lift without counterweight Very good control performance Starting torque accuracy at zero speed Weighting function without load cell Requirement for open loop solution To get rid of encoders ABB was only supplier able to do it successfully Customer’s opinion of ABB’s solution “Lift control with ACSM1 in open loop was more accurate than competitors’ solution with closed loop”
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