Founded in 1973 CT is a world leader in the Design, Manufacture, Marketing and Application of…. AC & DC Drives, Servo Drives Systems
Every Electric Motor is a Potential Application for Control Techniques products
Control Techniques - a history of Firsts & Success 1986 Launches Mentor - world’s first digital DC drive 1989 Launches first closed loop Flux Vector drive 1995 Introduces the world’s first universal AC drive 1988 Launches world’s first IGBT-based digital AC Drive We set the Benchmark for Drives 2002 Introduces world’s first “Solutions Platform” AC drive 2005 Introduces world’s first “knowledge” AC drive in small rating (Commander SK)
Digital DC / AC Drives Mentor : Digital DC 7.5 Kw to 750 Kw Commander SK : Simple ,Knowledge 0.25 Kw to 110Kw Unidrive SP : Solution Platform 0.75 Kw to 1.0 MW PV /EV - Fans & Pumps 5.5 Kw to 280 Kw
Other Products MC 204/216 - Motion Controller 4 to 16Axes CT START - Soft Starters 4 to 800 Kw Unimotor - AC Servo 1 to 70 Nm LSMV - Inverter Grade AC Motors 0.75 to 132 Kw Sincrovert - AC Spindle Motors 0.75 to 110 Kw
Worldwide Operations EUROPE ASIA PACIFIC AMERICAS
Drive Centres in North America Chicago Toronto Providence Charlotte Cleveland Distributors S.America Minneapolis (Head Office) Dallas
Drive Centres in Asia Pacific South Africa Australia Thailand India S. Korea China Indonesia (distributor) Malaysia Singapore Hong Kong Taiwan Vietnam (distributor)
New Delhi Application Center Kolkata Application Center Drive/Application Centers Indian Operations Ahmedabad Sales Office Pune Application Center Chennai Drive Center Nagpur Sales Office Hyderabad Sales Office
Control Techniques India Manufacturing & Support Facilities
12,000 Sq. ft. Purpose built factory
45 People ( of which 20 are Engineers) at Chennai
15 People (of which 10 are Engineers) in Branch Offices
Extensive Systems Capability
Over 150 Domestic Projects
Over 50 Export Projects
Complete Manufacturing facilities with Test Set Up
HIGH PERFORMANCE INTELLIGENT DRIVES FOR SYSTEMS
Digital DC Drives Mentor II - Flexible Systems Drive - 25 to 1850A Single & Four Quadrant 6-pulse Fully Digital 7.5 -75kW 100-300kW 300 – 750kW
Mentor Family Range 0.75-75KW H-370 mm W-250 mm D-195mm 300-750KW H-1355 mm W-450 mm D-510 mm 100-300KW H-423 mm W-450 mm D- 280 mm
MENTOR INPUT SPECS Voltage 220-480 V +/- 10% Suitable for Global Power Supplies NO Tap Selections Voltage 525 V and 660 V (Optional) Frequency 47-62 Hz. Wide tracking Range for PLL Temperature 40 Deg C for Power Derating upto 55 Deg C Electronics upo 55 Deg C
MENTOR features Phase Sequence Insensitive to Supply Phase Sequence Field Control Controlled Field Field weakening Inbuilt and Programmable Field Control Inbuilt (8 A) upto 210 A 20 A External
MENTOR I/O Analog Inputs 6 Nos. 4 No. Programmable (Volt) 1 No. Dedicated (Volt/Current Selectable) 1 No. Dedicated for Motor Thermistor Analog Outputs 4 Nos. 3 No. Programmable (0-10 Volt) 1 No. Dedicated (10Volt=200%Current ) Digital Inputs 10 Nos 2 Dedicated 8 Programmable Digital Outputs 7 Nos 1 Dedicated Relay 1 Programmable Relay 5 Programmable (Open Collector Type)
The most versatile DC systems drive in the world More than 3000 drives in India More than 125,000 drives in use world-wide
The most versatile DC systems drive in the world Control Techniques also Brand Labels Digital DC Drives for.. CGEE ALSTOM (FRANCE)
Unidrive Unified AC Drive with Solution Platform
Full Torque upto Standstill Excellent Speed, Current & Position Loop Very good Dynamic responses Servo Servo Applications Full Torque upto Standstill Excellent Speed & Current Loop Very good Dynamic responses Closed Loop Flux Vector Cranes / Hoists Process Lines Sectional Drives Full Torque to 1 Hz No Speed Loop Good Current Loop Mostly O/L Vector Constant Torque Load Fan/Pump / Conveyors Application Open Loop No Speed Loop No Current Loop V/f What you get… Type of Control
UniSP – The Universal Drive With Solution Platform 5 Modes of Operation: OL ( Open Loop V/f) OLV(Open Loop Vector) CLV(Closed Loop Vector) Servo Regen High Performance Powerful Flexible
UNISP SPECS Input Voltage 380-480 V +/- 10% NO Tap Selections Output Frequency 0-3000 Hz Suitable for High Frequency Spindle Input Frequency 47-62 Hz. Switching Frequency 3/4/6/8/12/16 KHz Quiter Operation Reduced Harmonics
Environmental Specs Ambient 40 Deg C 1 % per Deg C deration for 40- 50 Deg C Module IP rating IP 20 Nema 1 Special Cooling Fans Suitable for IP54 Extended IP rating IP54 Nema 12
SM-I/O Plus SM- PROFIBUS-DP SM-Applications SM-Universal Encoder Plus SM-CANopen SM- DeviceNet SM-INTERBUS SM-Applications Lite SM-Resolver SM- Encoder Plus SM-CAN SM-Ethernet SM-SLM SM-SERCOS
Unidrive SP with all front cover removed Option module docking bays Universal encoder connector (will accept 12 different types of encoder) Control Terminals with safety disable function as standard AC input power and motor connections Relay connections Cable support bracket
In addition to these critical parameters, Non-Time critical access to network should also be supported (e.g. Operator interaction / Drive set-up / Downloading application software / Diagnostics / Data logging)
Implementation can be by Centralized Intelligence or Distributed Intelligence approach
Configuration Possibilities Central Intelligence
All System Control Functions can be located in the Central Controller & transfer Demands + Feedbacks cyclically over the network. This is a typical Centralized Intelligence system Most PLC manufacturers prefer this approach even for Drive digital control for obvious reasons!!
Functionality Evolution Intel Basic with Parameter Access Winder, Digital Lock, Spindle Orientation, kWh Software, PID Advanced Position Controller added Winder, Flying Shear and Duty Assist Solutions PLCOpen Function Blocks Windows Software, Multi-Tasking Environment, Drive Programming Language (DPL) Function Block and Ladder Support, CTNet support. Constant Function Block Development Constant Fieldbus Development
Each Drive fitted with MD 29 AN Application cum Fieldbus Module with CT Net connectivity
All Line specific controls like Tension control, Loop Control etc.are set up in Application Module,located within drive module itself. This frees PLC from doing Maths functions related to Drive systems.
Control Techniques India Application Module : MD29AN PLC : Siemens, S7 - 400 Gateway Module : UniSP + SM Application + SM Profibus Scada System : WinCC V 5.1 Process Line : 4 Hi Non Reversible Skin Pass Mill End User : PT Essar Dhananjaya, Indonesia Project Team : Ganesh + Satish M1850R 325kw Recoiler M550R 90kw Exit Bridle Roll – M2 M550R 140kw Exit Bridle Roll – M1 M1850R 250kw Mill Stand M550R 140kw Entry Bridle Roll – M2 M550R 90kw Entry Bridle Roll – M1 M 1850R 225kw Uncoiler Drive Rating Motor Rating Application
Process Line : 4 Hi Non Reversible Skin Pass Mill End User : PT Essar Dhananjaya, Indonesia Project Manager: B. Ganesh + Satish 5 Mandays Post Commissioning Observation/Tuning 3 Mandays Commissioning 2 mandays SCADA Modification 1 Manday Interaction withAEC Panel Check 1 Manday Drive Software Simulation Test 3 Mandays Operation from CD with interlock 2 Mandays No Load motor Test 5 Mandays I/O Checking
Drives & Automation System Of Continuous Galvanizing Line PT.Essar, Indonesia.
The CR coils directly from 6 Hi/4 Hi mills are transferred to CGL lines.
The Strip passes through various processes to remove defects, etc.
CGL Process ( 1 of 3)
CGL being a continuous line, the coils passed through Looper.
Continuous annealing of coils takes place in an on line annealing furnace ( to clean the coils and anneal the coil to achieve desired hardness). The temperature of strip in this pre-heating oxidizing furnace would be between 550 and 680 C.
Then the coil is passed through Zinc pot where Zinc coating is carried out .
Zinc and Antimony of highest purity are used for coating sheets in a technologically advanced Hot-dip process. The bath temperature would be around 440 to 460 C. This operation is performed at a precise temperature set up.
CGL Process ( 2 of 3)
Due care is taken for pretreatment of substrate on which Zinc coating takes place.This consequently increases the life and performance of the galvanized sheets .
The Zinc Coating weight is controlled by the Air Knife Blowers
Control Techniques India Process Line : Continuous Galvanising Line Customer : Flat Products Limited, India End User : PT Essar Dhananjaya, Indonesia Contract value : US $ 630,000 Project Team : Bhanuprakash + Ganesh + Satish
1. Strip is Acid cleaned, passed through various parts of furnace to burn out oxygen
2. Temp. taken to 700 deg. and brought down to 400 deg for softening Strip and matching the Zinc temp.
3. Strip dipped in molten zinc
4. During process, important to maintain strip tension regulation to maintain Metallurgical characteristics of the strip
Ballarpur Industries – Yamunanagar – 21-section L&T Sectional Drive System Retrofit with Hi-Speed CT Net
Servall Board Project – 21 Section Asea Retrofit with Mentor II & MD-29
SPB, Erode – Rewinder-cum-Unwinder Brake Generator Retrofit of Stromberg DC System with Automation
Pennar Industries, Hyderabad: Over 8 projects (Slitter / Mill / Cut-To-Length with Automation)
150kW Coiler Analog Drive Power+Controls ( 2 Panels + Winder Control thru PLC ) 150kW Coiler Digital Drive Power+Controls + Winder Software Loop within Drive ( 1 Panel + less components+ less wiring ) DC Drive Retrofit Example
CT India Sample References High Performance Drive systems
160kW Centrifuge Systems ( 350 nos. supplied/commissioned in India )
MICO High Performance Testing – Over 500 Nos. AC Drives
Lucas TVS– over 50 High Performance AC Drive – Motor systems for SPM’s
Understanding the Common DC Bus Concept For AC Drive Systems
Drive System Configuration CT-Net Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R R R Brake Chopper Resistor 2000A
Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R DC Bus Configuration R Brake Chopper Resistor Rectifier Unit 6-Pulse Full wave Rectifier Low Input Harmonics Power Factor > 0.95 12-pulse configuration can be offered as optional 2000A R
Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R DC Bus Configuration R Brake Chopper Resistor Common DC Bus Connected to the UniDrive this configuration gives best performance in terms of sharing of Energy between the AC Drives Regenerated / Braking Energy from one drive is re-used by another motoring drive Motoring Drive draws less power from Mains . R
Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R DC Bus Configuration R Brake Chopper Resistor Charging Circuit Allows re-connection of any inverter to the already running system This pre-charging is a must. The charging resistor comes into the picture initially, allows the DC Link capacitors within the inverters to reach required potential before the pulses are allowed to fire the IGBTs. It gets disconnected, once this procedure is safely completed. R
Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R DC Bus Configuration R Brake Chopper Resistor UniDrive Fully Digital IGBT Controlled Micro-processor based On-Board 2 nd processor for Real Time processing of application programs High Speed Communication Field-Bus Connectivity All Real Time calculations like Diameter Computation , Tension Regulation , Accumulator Position control etc in 2 nd processor Master Line Speed generation within the Drive System R
Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R DC Bus Configuration R Brake Chopper Resistor Brake Chopper During the Braking phase, AC Motors give energy to DC Bus. If DC Bus Voltage exceeds 560V, IGBT-based Chopper gets automatically energized & the DC Bus voltage is kept around 600V The Brake Chopper has an in-built PI controller, allowing for controlled & smooth braking R
Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R R Regenerative Drive Trafo Elevatore 400V/660V Alternative DC Bus Configuration Using Mentor II Converter When the DC Bus Voltage increases beyond 600V, the regenerative Mentor II converter is energized. This returns the regenerated energy to the Mains thru a Step-up Transformer back to Mains. This configuration will also keep the DC Bus around 600V Advantages: No wastage of regenerative energy in the resistor Disadvantage: High Cost R
Colour Coating AC Drives and Motors COMMON DC-BUS 560V R R R Alternative DC Bus Configuration Using 12-Pulse Configuration Features Double Secondary Transformer, Phase Shifted at Input to Rectifier Advantages: Power Factor is near Unity for all load conditions Very low Harmonics Y IPT R