Abb Ltd. · SIX:ABBN
Abb — Mining User Conference 2017
15 slides from Abb's conference presentation, May 2017
Slide 1: IGBT Utilization and Life Cycle
New illustration is coming MINING USER CONFERENCE, MAY 3-5, 2017 IGBT Utilization and Life Cycle With heavy duty load requirements on Electric Rope Shovels Boris Rathmann, Product Manager Shovel & Dragline
Slide 2: Outline of presentation
Outline of presentation Joy Global – ABB Success Story Dynamic AC Drives for Electric Rope Shovels Load cycle and live time requirements IGBT physics and mining environment IGBT analysis and continuous improvements Product quality process Summary May 3-5, 2017 Slide 2 Mining User Conference 2017, St
Slide 3: IGBT AC Drives for Electric Rope Shovels
IGBT AC Drives for Electric Rope Shovels Joy Global – ABB Success Story Bild Canada May 3-5, 2017 Slide 3 Mining User Conference 2017, Stockholm
Slide 4: Joy Global – ABB Success Story
IGBT AC Drives for Electric Rope Shovels Joy Global – ABB Success Story Cooperation with P&H / Joy Global / Komatsu Started 2005 – Demanding requirements for ABB AC Drives • ACS800 Mining Drives for heavy duty environment • Switchgear enforcement for high shock and vibration • One inverter module si
Slide 5: Load cycle and live time requirements
IGBT AC Drives for Electric Rope Shovels Load cycle and live time requirements Hoist Power, Torque, Speed / Load Cycle Hoist (40s) IGBT Power Plate Temperature / Load Cycle Hoist (50s) 4000 25000 3500 20000 3000 2500 15000 2000 1500 10000 1000 5000 500 0 0 176.505 158.00549 159.75456 161.65179 163.5
Slide 6: Physics and mining environment
IGBT AC Drives for Electric Rope Shovels Physics and mining environment IGBT-Modules EconoPack FS450R12KE3 Current: 450A Peak: 900A Voltage: 690V Operation temp.: 125°C Peak temp.: 150°C May 3-5, 2017 Slide 6 Mining User Conference 2017, Stockholm
Slide 7: Physics and mining environment
IGBT AC Drives for Electric Rope Shovels Physics and mining environment IGBT PowerPack for ABB Drives ACS800 Delivered since 2005 in different revisions – Challenges for heavy duty mining • Shock and vibrations • Extreme temperatures -40 to +50°C • Dynamic load cycle with temperature differences • C
Slide 8: Analysis and continuous improvements
IGBT AC Drives for Electric Rope Shovels Analysis and continuous improvements Supplier: Infineon Transistor and Diode chip EconoPackTM FS450R17KE3 elements are connected with Transitor +Diode bond wires 3 phase module New is changed bonding wire Principles of design and soldering expanded bond wires
Slide 9: Analysis and continuous improvements
IGBT AC Drives for Electric Rope Shovels Analysis and continuous improvements EconoPackTM FS450R17KE3 96 power elements for 1 shovel Heatsink after dry-out of 576 IGBTs per machine thermal interface material New TIM as phase shift Principles of Thermal material, with stencil and Interface Material (
Slide 10: Quality process: ABB 4Q Process Improvements
IGBT AC Drives for Electric Rope Shovels Quality process ABB 4Q Process Improvements Steps to be successful 4Q Process – Q1 Q1 - Measure Q2 - Analyze • Various on-site measurements and site surveys Define opportunity Investigate to Identify and confirm root causes understand the current state in det
Slide 11: Analysis and continuous improvements
IGBT AC Drives for Electric Rope Shovels Analysis and continuous improvements Test stand to check each IGBT New device for thermal before release to installation grease application Visual inspection Precisely given amount in Electrical test specified pattern Output waveform scope check Precisely lai
Slide 12: Analysis and continuous improvements
IGBT AC Drives for Electric Rope Shovels Analysis and continuous improvements CROWD Temp&Current OLD SOFT 1000 140 ACS800 Drives Firmware DTC (Direct Torque Control) 800 120 600 100 Change system control program 400 80 – Analysis of load cycle and high torque requirements 200 60 – Changing switching
Slide 13: Quality process: ABB Process Improvements
IGBT AC Drives for Electric Rope Shovels Quality process ABB Process Improvements Setup for 8 R8i inverter module testing Picture: R8i Ongoing Reliability Test container Ongoing Reliability Test (ORT) since 2013 with samples from the serial production Accelerated Life Testing (ALT) simulation of
Slide 14: Summary
IGBT AC Drives for Electric Rope Shovels Summary Global fleet of Electric Shovels AC EU 1 Number of IGBTs 7000+ Failure rate below 2% Product life cycle 12 NA 33 years Improved lifetime by MEA 7 reduced thermal cycling Ongoing reliability testing for Drives modules Established AC Drives SA 34 APA 8
Slide 15: Slide 15