Business Unit Metals — 1 ABB Industrial

Topics Drives System n Automation System (Level 1) n © Business Unit Metals - 3 - n Manufacturing Execution System (Level 2)

Topics Drives System n Automation System (Level 1) n © Business Unit Metals - 4 - n Manufacturing Execution System (Level 2)

Drives System for all metals applications n Applications Hot Rolling Mills n Cold Rolling Mills n Profile Rolling Mills n Processing Lines n n High performance Drives Fast torque step rise time n High dynamic speed accuracy n Excellent process controllability n n Wide range low voltage AC Drives From 5. . . 5140 k. VA, 380. . . 690 V n Modular configuration © Business Unit Metals - 5 - n Stand-alone n Multidrive (Common DC bus configuration) n n Wide range DC Drives From 22 to 5150 A DC, 380 to 1000 V AC n Modern rebuilt kit for revamps n

© Business Unit Metals - 6 - Direct Torque Control

DTC has 25 microsecond control loop Traditional PWM: • Control in short steps to avoid overshooting • Control loop time 1 -3 ms because of modulator Frequency reference V/F ratio Vector control: • Tachometer feedback required • Control loop time 1 -3 ms because of modulator Speed control Torque control V Modulator f V Modulator AC AC f T DTC principle: © Business Unit Metals - 7 - • Torque controlled by a single step • No risk of overshoot with fast 25 s control loop n n Speed control Torque control AC Backlash appears in gearboxes and couplings. In backlash range motor may accelerate leading to backlash impact. Fast DTC control limits impact. Mechanical resonances often appear due to elasticy of shafts and inertias of motor, gearbox and driven machine. Fast DTC attenuates the resonances.

Direct Torque Control n Advanced drives control Torque Reference Speed control Torque Reference Controller REF Torque and Flux Comparator Torque and Flux PID Motor Model = Switching Logic ~ Switch positions Voltage © Business Unit Metals - 8 - Current Calculated Speed DTC CORE 3~

DTC, Direct Torque Control, fast and gentle 1, 00 New Current level Current 0, 50 Servo performance without high switching frequency (no useless switching) Time 0, 00 Torque © Business Unit Metals - 9 - DTC Vector New Torque level Always to the correct value by single switching Frequent torque monitoring prevents overshooting Torque is always correct.

Direct Torque Control increases drive performance n Advanced drives control Fast Torque Step Rise Time High Dynamic Speed Accuracy Torque Open Loop DTC Speed © Business Unit Metals - 10 - Closed Loop Flux vector Open loop DTC <5 msec Open loop flux vector > 100 msec Closed loop flux vector 10 to 20 msec Speed error Open loop DTC 0. 4 %sec Open loop flux vector 3. 0 %sec Closed loop flux vector 0. 4 %sec

DTC, Less stress to mechanics Backlash appears in gearboxes and couplings. In backlash range motor may accelerate leading to backlash impact. Fast DTC control limits impact. n © Business Unit Metals - 11 - n Mechanical resonances often appear due to elasticity of shafts and inertias of motor, gearbox and driven machine. Fast DTC attenuates the resonances.

Drives system reduces energy consumption n Multidrive configuration n n Common DC-Bus possible © Business Unit Metals - 12 - To overriding control Energy consumption is reduced n n Drive. Bus Compensating other loads is possible Dimensioning of incoming sections and transformers or supply can be smaller n means lower investment Process Section Line Entry Section

Hardware with Modular Construction Drive Section(s) Supply Section ACU ICU DSU TSU Common DC Bus Control Section(s) Drive. Bus To overriding control ~ ~ AMC AMC Inverter Diode or Thyristor Supply Unit Inverter PC Tools: Drive Windows © Business Unit Metals - 13 - AC

Intelligent Control Panel For global use - display with ten languages n Easy monitoring - four-line display n Supports maintenance - fault memory n Removable panel n © Business Unit Metals - 14 - n Quick and easy commissioning with the parameter copying feature n Selection and parameterization of application macros

Commissioning and Maintenance Drives Window Tool Displaying system configuration n Auto tuning functions n Monitoring actual signal values n Fast and accurate measurements with data logger n Viewing and changing parameters n Logging faults n Logging events n Local control of drives n © Business Unit Metals - 15 - n Controlling and debugging applications n Backup and restore

Topics Drives System n Automation System (Level 1) n © Business Unit Metals - 16 - n Manufacturing Execution System (Level 2)

Integrated control system Computer room Hydraulic room OIT & MES Server Control rooms (entry, proc. , exit) Switch-House Event / Alarm Hardcopy . . . MMS, TCP/IP Drive. Bus . . . © Business Unit Metals - 17 - Drive . . . Drive n Reference Generation & Seq. n Auxiliary Logic & Sequencing Entry . . . Drive n Reference Generation & Seq. n Auxiliary Logic & Sequencing n Strip tracking, Presetting & Recording Process . . . Drive n Reference Generation & Seq. n Auxiliary Logic & Sequencing Exit Other functions

Availability and integration of information n Operator. IT n One single interface for all applications n Data integration n © Business Unit Metals - 18 - n From production data to alarm & events Operation efficiency

Operate. IT, Keeping IT together. . . Metals Customer need a way to keep together all different aspects of plant and process entities (objects) Functional Product Description specification Simulation Production order Operator interaction Graphics Stock Cost of report operation © Business Unit Metals - 19 - Control Production schedule Production report Quality report Profile data Maintenance Record

User Interface - Automatic from Object to display n You can always find out in what graphics an object is represented n n Right mouse click to show the context menu and look in the Reference Item Makes it possible to navigate for examples from the Trend to the graphic n Graphic to graphic n n Alarm List to the graphic n © Business Unit Metals - 20 - n . . . Automatically configured

Process Graphics - General n State of the art process graphics n n Use the latest technology for creating graphics Openness Make use of the extensive amount of Active. X control available on the market n © Business Unit Metals - 21 - n Include any photos, scanned images, or live images of your choice

Special SW & HW for the needs of the rolling mill process n Rolling Mill Control Ultra fast communication between controller n Precision time marking for ms timing between duty cycles n Fast connection to pulse generator and absolute encoder n Fast Drives interface n © Business Unit Metals - 22 - n Special program building block for efficient engineering on the Control. IT platform

Control. IT AC 800 Hardware Modular and flexible concept, DIN-rail mounted n Scalable hardware various CPU variants n Built in RS 232, Module. Bus and redundant Ethernet n Optional communication modules n Hot swap I/O modules n Local and remote I/O options n © Business Unit Metals - 23 - n Very low power consumption n Industry quality hardware with excellent EMC and MTBF properties

Control. IT AC 800 PEC Hardware IBM Power. PC 750 FX n 500 MHz n 128 Mbyte RAM n 16 Mbyte Flash Memory n © Business Unit Metals - 24 - n Cycle times: n Control Builder Layer 1 ms n C-Code Layer 1 ms. . . 100µs n VHDL Layer 100µs. . . 1µs

Control. IT AC 800 PEC Hardware Any-IO, PEC 800 -AIO-CEX 2 x Any-IO CPU module, PEC 800 -CPU 2 x Ethernet 100 MBnd 1 x Serial RS 232 Up to 12 communication modules on Any-IO CEX Bus n 2 nd Any-IO can be used for e. g. Profibus n Up to 6 Profibus communication Interfaces in CEX Bus n Optical Module: © Business Unit Metals - 25 - n One link for Module bus for S 800 or Drive communication n Other links can be used for special AC 800 PEC I/O or fast CPU point to point communication n Optical Module, PEC 800 -OM 2 x Optical Module with 3 or 6 optical links per module Stackable up to 3 modules Up to 7 S 800 I/O clusters on the optical Module. Bus n Up to 12 S 800 I/O modules per cluster n n n 7 x 12 = 84 I/O modules Remote I/O via Profibus DP up to 32 Stations on a Profibus Segment n up to 24 I/O Modules per Station n

Control. IT, Choose Your Language n Standard Easy to use IEC 61131 -3 n All five languages supported Ladder Diagram (LD) n Function Block Diagram (FBD) n Structured Text (ST) n n Instruction List (IL) n © Business Unit Metals - 26 - n Sequential Function Chart (SFC) Additionally n Control Module Diagram

Control Builder M n Fast, incremental, bump less online changes n Powerful Test & Simulation n Off-line program check and simulation n Single stepping n On-line facilities © Business Unit Metals - 27 - n Easy made user defined function blocks for unmatched flexibility n Saves Engineering work n On-line help and manuals Make your first application in 30 minutes!

SW configuration for Processing Lines HMI o. Line Supervision o. Setpoint Management Overriding Controls o. Reference Generation o. Emergency o. Auto Slow Down o. Weak Point tracking © Business Unit Metals - 28 - Drives Controls o. Coiler Control o. Roll Control o. Looper Control o. Roll Control o. Bridle Control o. Coiler Control o. Roll Control

User Interface - Structure for Processing Lines Main Menu Start up Conditions Operation Mode Mimics Presetting Menu Process Entry Exit Presetting per Coil - Entry - Process - Exit Process Data © Business Unit Metals - 29 - Power Supply Hydraulics Gear Lubrication Strip Tracking Automatic Operations System-, Alarm-, Event- & Status-Lists Process Entry Exit Start Conditions Start conditions Threading Operation (Status List) Start Conditions Coil Preparation Entry, Process, Exit Coil Transport Entry Coil Transport Exit Sequences

© Business Unit Metals - 30 - Metals Solutions based on Operate. IT Process

© Business Unit Metals - 31 - Metals Solutions based on Operate. IT Sequencing

© Business Unit Metals - 32 - Metals Solutions based on Operate. IT Presetting

© Business Unit Metals - 33 - Metals Solutions based on Operate. IT Status

Electrical Equipment for Processing Line Continuous Processing requires: ü For Mechnical equipment ü Welding at Entry and cutoff at exit ü Entry and Exit Looper for coil exchange © Business Unit Metals - 34 - ü For Electrical Equipment ü The strip speed must be constant and continuously adjustable within wide limits ü Acceleration / deceleration should be performed quickly and steadily without producing any impact forces ü The drives must always be well synchronized or operate in groups in relative synchronism ü With defined tension distribution, which can be adjusted at certain groups in the strip processing line, the strip has to be moved over long distances and many rolls symmetrically to the axis of the line ü The tension has to be produced by part of motor running in motoring mode and part of motor running in generating mode. ü And More …… But We Are not only a products supplier, We know more about metals application ….

Line Control Overriding control & Reference generation function Main function: © Business Unit Metals - 35 - o o o Overriding control and interlocking Automatic sequences for threading and unthreading Automatic slow down at pay off reel strip tail end Strip / Weak point tracking and strip positioning Operation mode selection Velocity speed and dv/dt reference generation

Line Control Strip Tracking & Setpoint Management © Business Unit Metals - 36 - Main Functions: o o Weld & Weak Point Tracking Line Section Setpoint Management Interface with MES System Data Recording

Line Control Coiler Drive Control © Business Unit Metals - 37 - Main Functions: o o o o Basic drive application functions Diameter calculation Tension torque reference Calculation of moment of inertia Acceleration/deceleration torque compensation Delta n acceleration compensation Strip tail end calculation Positioning

Line Control Roll/Bridle Drive Control Main Functions: o Basic drive application functions o Load share control function n Speed controlled drive with window control n Speed controlled drive with droop control n Speed controlled drive with load share control Furnace Top Guide Roll Dancer Roll © Business Unit Metals - 38 - Entry Looper Inlet Seal Roll Bridle 2 TM 1 Exit Looper Outlet Seal Roll Bridle 3 TM 2

Line Control Looper drive application functions Main Functions: o Basic drive application functions o Tension torque reference © Business Unit Metals - 39 - o Looper positioning

Topics Drives System n Automation System (Level 1) n © Business Unit Metals - 40 - n Manufacturing Execution System (Level 2)

MES for Processing Lines Plant Wide Planing & Reporting (ERP / SCM) © Business Unit Metals - 41 - Material Identification Production Order Management Schedule Management Process data acquisition OCS (Level 1) Combining Business Needs with the Manufacturing Process Improving Mill-Efficiency by Real-Time Integration with ERP Reporting

MES (Level 2) Functionality n Coil in Stock © Business Unit Metals - 42 - Coil Preparation Processing Receive Data from ERPSystem

MES (Level 2) Functionality n n Coil in Stock © Business Unit Metals - 43 - Coil Preparation Processing Receive Data from ERP-system Production scheduling

MES (Level 2) Functionality n © Business Unit Metals - 44 - Coil Preparation Processing n Production scheduling n Coil in Stock Receive Data from ERPSystem Material Tracking

MES (Level 2) Functionality n © Business Unit Metals - 45 - Processing Production scheduling Material Tracking n Coil Preparation n n Coil in Stock Receive Data from ERPSystem Material Identification

MES (Level 2) Functionality n © Business Unit Metals - 46 - Processing Production scheduling Material Tracking n Coil Preparation n n Coil in Stock Receive Data from ERPSystem Material Identification n Preset Management

MES (Level 2) Functionality n © Business Unit Metals - 47 - Material Tracking Material Identification n Preset Management n Processing Production scheduling n Coil Preparation n n Coil in Stock Receive Data from ERPSystem Data Acquisition

MES (Level 2) Functionality n Material Tracking Material Identification n Preset Management n Data Acquisition n Processing Production scheduling n Coil Preparation n n Coil in Stock Receive Data from ERPSystem Coil Reports © Business Unit Metals - 48 - n Production Reports

MES (Level 2) Functionality n Material Tracking Material Identification n Preset Management n Data Acquisition n Roll Change Production scheduling n Coil Preparation n n Coil in Stock Receive Data from ERPSystem Coil Reports © Business Unit Metals - 49 - n Production Reports n Roll Change

MES - Equipment. Manager “The operational goal is to keep plant, equipment and facilities available with minimum downtime at minimum cost to maximize revenue and profit” (Source : Gartner Group) Keep equipment available with minimum downtime n Maintenance triggers and alarms n Downtime fault reports n Operation time, start, stop are monitored and accumulated © Business Unit Metals - 50 - n