Professional Documents
Culture Documents
1997
MITSUBISHI
ELECTRIC
A Quarterly Survey of New Products, Systems, and Technology
Vol. 79/Jun. 1997 Mitsubishi Electric ADVANCE
CONTENTS Editor-in-Chief
Akira Yamamoto
OVERVIEW
The Present and Future Prospects for Electrical
Equipment in Iron and Steel Plants
by Shuuhei Niino*
I
ron and steel plants have always played a leading role in the develop-
ment and introduction of new industrial technologies. A number of
pioneering process innovations have now reached the stage of practical
implementation. These include world firsts such as continuous casting
strip mills, which link the caster directly with the hot strip process, and
continuous hot-rolling mills in which strips are welded together to form an
endless rolling process. Work is proceeding actively on technologies for
mini-mills and inline strip processes (ISPs) to reduce the size of installa-
tions, and on CALS research (which in the context of iron and steel plants
means both commerce at light speed and continuous acquisition and life
cycle support) to reduce engineering and procurement costs.
Electrical products are responsible for performing supervision, measure-
ment and control functions in iron and steel plants, and thus have a central
role to play not only in plant operation but also in ensuring that the latest
technologies can be adopted and product quality improved.
Recent Mitsubishi Electric products for iron and steel plants are charac-
terized by fast, highly compatible control systems with sophisticated func-
tions. Sensitive and accurate sensors and advanced control techniques are
playing their part in fully automated processes, where integrated electrical,
instrumentation and computer (EIC) environments that monitor and con-
trol operations are improving product quality. Clean, environmentally
friendly sources of electrical power, with power factors of unity and mini-
mal high-order harmonic current, are being supplied, as are AC main drive
systems that are largely maintenance free and provide high-speed response
thanks to the adoption of gate turn-off thyristor (GTO) inverters.
June 1997 1
TECHNICAL REPORTS
Baoshan Steel No. 2 Hot-Strip Mill (China) Sizing press, rougher mill, finisher mill 96
Posco Kwangyang Thin Slab Hot-Strip Mill (South Korea) Finisher Mill 96
Hanbo Steel No. 2 Hot-Strip Mill (South Korea) Sizing press, rougher mill, finisher mill 96
Posco Pohang No. 3 Plate Mill (South Korea) Edger, finisher mill 97
Key
MELPLAC-750 PLANT CONTROLLER
FSCC Furnace supervisory control computer
MSCC Mill supervisory control computer DO Digital output MDS Monitoring diagnosis system
AI Analogue input DR I/O Dataway remote I/O OPS Operator station
AO Analogue output DT/CS Delay table/Crop shear QOC Quick open control
APC/AGC Automatic position control/Automatic ENT/DEL Entry/Delivery RAWC Rougher automatic width control
gauge control FM master Finishing mill master RM Roughing mill
AQC Automatic quality control FM roll change Finishing mill roll change ROT & DC master Runout table & DC master
DC Down coiler FM-1 Finishing mill-1 SCC Supervisory control computer
DI Digital input FM-2 Finishing mill-2 SP/RM Sizing press/Roughing mill
*Kazunobu Takami and Yoshiaki Nakagawa are with the Power @ Industrial Systems Center.
Steel Corporations No. 2 hot-strip mill (China), for the process control computer and DDCs have
Posco Corporations No. 1 thin slab hot-strip been combined with increased data sharing.
mill and Handbo Steel Corporations No. 2 hot- A high-speed, large-capacity DDC features
strip mill (South Korea), and Yiehloong 0.2s/bit arithmetic, a 64K-step program
Corporations hot-strip mill (Taiwan). memory and 128Kword data memory. This en-
ables the number of CPU modules to be reduced
Control Systems by a factor of five and the number of cards per
Fig. 1 shows a configuration of the newest con- CPU module to be reduced by a factor of four.
trol system for state-of-the-art hot-rolling mills. All process control signals are input or out-
The system consists of an industrial computer put via dataway remote I/O units which are
system for process control, the MELPLAC-750 connected with an integrated network (MDWS-
controller, man-machine interface, dataway re- 600S1). Process signals can be shared and con-
mote I/O units and networking equipment. The troller backup is simplified.
following paragraphs list major system features. Integration of the operator consoles for the
A high-speed, large-capacity integrated net- process control computer and DDCs permits a
work system provides 100Mbps and 32Kword unified approach to system control. The con-
capacity, allowing the integration of previously trol desk has been simplified and the number
separate dataways for the industrial process of operators reduced through use of touch-screen
control computer, direct digital controllers CRT monitors.
(DDCs) and a monitoring system. User consoles
OPS-750 OPS-750
ICS ICS ICS ICS
MDWS-600S1 MDWS-600S1
MDWS-600S1 MDWS-600S1
Key
DR I/O Dataway remote I/O OPS-750 Operator console
ICS Process control computer P550 Direct digital controller
MDWS-600S1 MDWS-600S1 integrated network P750 Direct digital controller
June 1997 3
TECHNICAL REPORTS
Capacity and performance requirements on need. This is especially significant, since many
electrical equipment for steel processing lines of the motors in steel processing lines are in
have increased in response to development of high places or other locations with limited ac-
large, high-performance lines and high-value- cess. Second, independent speed control for
added production. This article provides an over- motors in lines with numerous helper rollers
view of electrical equipment Mitsubishi Electric enables finer coordination of these rollers than
has designed and manufactured to meet these is possible using multiple DC motors under a
needs. common thyristor-controlled power supply.
Third, in an AC system, rollers for motoring
Drive Systems and dragging can be connected to a common
Variable-speed AC motor drive systems have thyristor converter allowing exchange of DC
brought a number of improvements to steel power, and with that, the use of smaller-capac-
processing lines. First, AC motors do not re- ity power supplies than in DC motor systems.
quire the regular maintenance that DC motors Finally, Mitsubishi Electric has developed and
SCC
LAN
BUS1
RASP RASP
MULTI BUS
TCP/IP ENT ENT CENT EWS EWS
PCPU DEL DEL CENT PCPU
TCP/IP (POLU) (POLU) (POLU) TCP/IP (POLU) MELSUCSES
H/C
RIO RIO SECNET SECNET SECNET RS232C E-CRT
RIO PRT
PULPIT
WELDER CCTV
Key
BUS1 MDWS 600SI integrated control bus MELSEC MELSEC sequencer
CCTV Closed-circuit TV camera MELSUCSES MELSUCSES software development workstation
CENT Center PLC MULTI BUS Multiple CPU bus
DEL Delivery PLC PCPU Peripheral CPU
E-CRT Electrical CRT POLU POL processor
EER Electrical equipment room PRT Printer
ENT Entry PLC RASP RAS processor
EWS Engineering workstation RIO Remote I/O
H/C Hard copy SCC Supervisory control computer
H/T High tension panel SECNET MELSEC network
L/T Low tension panel SOL PNL Solenoid valve panel
LAN Local area network SPECIAL INST Special instrumentation
LSD Large screen display VVVF Variable-voltage variable-frequency motor drive system
MCC Motor control center X-TER X-Windows terminal
*Seiji Takayanagi and Shigeharu Hamada are with the Power & Industrial Systems Center.
June 1997 5
TECHNICAL REPORTS
proven a sensorless vector control system for SES workstation which supports MELPLAC-750
helper rollers that dramatically simplifies larger software development and maintenance.
systems where 200 to 300 helper rollers are used. MELSUCSES allows users to automatically gen-
erate control software using the Macro Control
Control Systems Diagram (MCD) control specification language.
The need for faster processing lines with better It has database capabilities that provide a cen-
quality product and less labor-intensive opera- tral repository for storing equipment lists and
tion translates into demand for faster, more so- other data on plant facilities. The user can in-
phisticated and more extensive control systems. corporate monitoring functions into MCD pro-
Mitsubishi Electrics MELPLAC-750 plant con- grams that allow MELSUCSES to serve as a
troller meets these needs by combining electri- plant monitoring tool. Finally, the system sup-
cal and instrumentation control functions, and ports standard software packages that can dra-
offering high-speed sequence control, advanced matically reduce software design time.
arithmetic control, feedback control and batch Demand for faster production of higher qual-
control capabilities. ity products is accompanied by competing de-
Fig. 1 shows the configuration of a state-of- mand for labor savings that requires
the-art steel processing line based on the MEL- development of more sophisticated operator
PLAC-750 plant controller. The system features consoles. The Mitsubishi Electric OPS-750 re-
high-speed RISC processors and dedicated con- alizes the high-speed response and other per-
trol processors, remote I/O stations that mini- formance improvements needed to manage
mize wiring requirements for process I/O, large steel-processing facilities. The OPS-750
encapsulated software components that facili- has been designed to work with the
tate software reuse and support online software corporations LVP 70" video projector, allowing
component maintenance, and extensive self-di- the OPS-750 to display multiple data and con-
agnostic functions for improved reliability. trol screens and video signals from the plants
The corporation is also offering the MELSUC- CCTV systems on a single large screen. The
Strip Entry loop tower Annealing furnace section Delivery loop tower
Tracking
Coating thickness change control Preset
Rectifier
Strip
Fig. 3 Coating thickenss control system for electrolytic galvanizing or tinning lines.
June 1997 7
TECHNICAL REPORTS
Improvements in high-power gate-turn-off thy- systems. Two-level IGBT inverters are suitable
ristors (GTOs) and insulated-gate bipolar tran- for capacities up to 800kVA, three-level IGBT
sistors (IGBTs) along with better electric motors inverters up to 3,000kVA, and three-level GTO
and control technology have allowed develop- inverters can handle up to 20,000kVA. GTO
ment of a wide range of voltage-controlled inverters have already been proven in main
inverter drive systems for main and auxiliary motor-drive applications of 6,000kW with a
motors in steel rolling mills. This article intro- 225% overload capacity, and are currently be-
duces key elements of these drive systems, in- ing tested in 10,000kW applications.
cluding GTO and IBGT inverters, and main and Table 1 lists the specifications of the inverter
auxiliary motors. units. In small- and medium-capacity two- and
three-level IGBT applications, a thyristor con-
Variable-Speed AC Drive Units verter distributes DC power, allowing a single
The diagram in Fig. 1 shows the target applica- converter to be shared among multiple motors,
tion spectrum of several variable-speed AC drive which lowers system capacity requirements.
2,000
1,800
Three-level GTO inverters
1,500
600
Current noncirculating
cycloconverters
*Yuji Sano and Ichiro Serikawa are with the Nagasaki Works.
Pedestal
Bed
Three-level GTO inverters for large-capacity Variable-Speed Synchronous Motors for Steel
applications employ a high-power-factor in- Rolling Mills
verter on the input side that reduces harmonic Synchronous motors can be operated with a
energy and reactive power, thereby improving power factor of unity, have a lower power-source
the power-supply environment. capacity than induction motors, and are rela-
tively small and lightweight. Motors for rolling
GTO Inverters mills require substantial electrical overload
Main motors for rolling mills have previously capacity and the mechanical strength to endure
used cycloconverter drive systems. GTO invert- the large shock torques that are generated when
ers are now taking over applications from 4,000 slab is between rollers. Fig. 3 shows the con-
to 20,000kVA due to the development of six- struction of a reversing synchronous motor for
inch devices rated at 6kV and 6kA and four- rolling mill applications.
inch devices rated at 4.5kV and 4kA.
Fig. 2 shows a photo of the main circuit equip- STATOR COIL. To provide the strength needed to
ment. The converter and inverter are combined, withstand rolling shocks, the stator coil and
and identical main circuit units are used for core are integrated, and then a vacuum pres-
each phase, facilitating maintenance. The sured impregnation process is used to draw in
equipment size has been reduced through use epoxy resin insulation to form a durable coil
of water cooling. assembly.
June 1997 9
TECHNICAL REPORTS
Table 2 TM Series Induction Motors mine the stress on each motor component.
Type Model External Appearance
These data were used to raise motor reliability
and resistance to shock.
Fully enclosed, frame TM-E
cooled Mitsubishi Electric has developed both AC
motors for rolling mills and their inverter drive
systems. Recent technologies improve power
Open (or fully enclosed) TM-BD
efficiency, reduce equipment size and lower
with duct ventilation (TM-ED) maintenance requirements.
Computer systems for controlling iron and steel O PEN-SYSTEM ARCHITECTURE WITH REALTIME
plants are shifting towards open-system archi- PERFORMANCE. The MR Series maintains the
tectures and right-sizing to support better tai- realtime operating system concept, realtime
loring of systems to applications. Such systems response and facile system analysis proven in
provide an increasingly diverse range of func- the corporations previous process controller,
tions that contribute to optimizing the behav- offering a POSIX 1003.1a-c-compliant realtime
ior of the overall system. Concerns about Unix platform with open-system specifications
realtime performance, reliability and maintain- and an outstanding software development envi-
ability that guided the design of previous sys- ronment. This provides the previously unavail-
tems are now being supplemented by an able combination of realtime performance and
increasing orientation toward the use of hard- open-system design. Fig. 1 shows the response
ware and software designs based on industry of MI-RT, Mitsubishi Electrics rugged realtime
standards.This r eport covers industrial computer Unix operating system for the MR Series com-
system configuration concepts and introduces the puters. The MR3000 has a maximum time lag
MR Series of industrial computer systems. of 0.1ms between an event and startup of a high-
Table 1 MR Series Specifications
Central Concepts Table 1 MR Series Specifications
The 1990s have placed various demands on in- Software
*Kazuo Sena and Noriyoshi Hiratsuka are with the Power & Industrial Systems Center.
June 1997 11
TECHNICAL REPORTS
Fig. 1 Response of MI-RT realtime Unix. FLEXIBLE SYSTEM CONFIGURATION. A steel mill
control system consists of discrete components
priority program triggered by the event when connected together including a computer for
multiple programs are executing simulta- high-level control, a programmable logic con-
neously. The systems response, 100 MIPS per- troller for low-level control and an instrumen-
formance and communication functions tation system. The networking capabilities of
support polling at 20~40ms intervals for hot- the MR3000 Series allow these various compo-
strip mill control with regular transmission of nents to be linked flexibly into an integrated
system status and fault data. Fig. 2 shows MI- system. The MDWS-600S1 integrated control
RTs development lineage. bus provides realtime response where required.
POSIX-compliant High-performance
Unix Unix
The POSIX standards facilitate porting of Enhanced security (DOD Level B security)
software between Unix-like operating systems. Transaction functions
Microkernel
Realtime Unix
(Lynx OS, HP-RT)
Disk
Disk Disk
Disk
Printer Printer Printer Printer
Audio Disk
Speaker output Software development
device
workstation
Ethernet
DISK ARRAY
xN
Printer Server
Disk Disk
Workstation
Key
PLC PLC AQC Advanced quality control
PLC Programmable logic controller
SCC Supervisory control computer
Application software
Application interface
File management
Middleware interface
June 1997 13
TECHNICAL REPORTS
Ethernet and ATM networking capabilities The MR Series of industrial computer systems
meet the need for open systems and maintains support for legacy applications while
multivendor operation. Other communication offering customers the advantages of a realtime
capabilities include a line server for easy con- Unix-based open system with a wide variety of
nectivity to general-purpose computing connectivity options.
equipment as well as Mitsubishi control equip-
ment. Fig. 3 illustrates the configuration of a
control system for hot-strip mills using the
MDW-600S1 integrated control bus.
Software Configuration
In modern control systems, portable applica-
tion programs are preferred to application pro-
grams bound to a particular execution platform.
Applications for MR Series computers can also
be executed on workstations since the MI-RT
operating system is Unix based. Middleware for
iron and steel plants permits application soft-
ware to be developed independently of the ex-
ecution environment. Fig. 4 shows the software
configuration. The middleware allows applica-
tion programs using a common set of functions
to be programmed through a simple user inter-
face. The following paragraphs list the features
of software design.
An application program interface (API) con-
sistent with the corporations previous com-
puter systems allows customers to easily
migrate existing applications.
The middleware is divided into execution-
machine-dependent and execution-machine-
independent functions, and a standard interface
(called a middleware interface, MWI) has been
established between these two domains. By
developing a MWI for each function, middle-
ware can be adapted to each execution machine.
Higher testing efficiency and reduced program-
ming requirements lower cost and raise qual-
ity.
The MI-RT realtime Unix operating system
allows functions to be distributed over an
Ethernet LAN, allowing the use of personal-
computer-based operator terminals, protocol
converters and other intelligent devices. Middle-
ware support for these devices is under devel-
opment.
A trace function that records operating his-
tory at the variable call level can be incorpo-
rated to facilitate problem analysis.
This report introduces the MELPLAC-750 in- count, and by use of highly reliable devices with
tegrated control system for state-of-the-art steel lower incidence of failure. Parallel power supplies
mills. The system consists of a process control can be installed so that a single power-supply fault
computer, plant controller and operator consoles will not stop the system. Fault diagnostic func-
built on an integrated control network that tions in each device support a first fault func-
supports a shared process I/O database (Fig. 1). tion that assists in locating failures. The
application program memory has a battery-free
Controller Features backup function.
The processing unit, which incorporates a high-
speed RISC processor and dedicated processor, Network Features
performs bit arithmetic operations in 0.2s. The The MDWS600S1 integrated control network
controller has a 64k-step POL program capac- (MDWS stands for Mitsubishi dataway system)
ity for controlling electricity. The instrumen- is an FDDI-compliant high-capacity network
tation control capabilities extend to 320 loops. with a bandwidth of 100Mbps. Use of a distrib-
A multiprocessor configuration is available to uted processor management system (DPMS)
distribute the processing load and improve con- allows applications using interprocess commu-
trol performance. nication to be insulated from the complexities
Software encapsulation and modularization of the network layer. A cyclic communication
support software development in top-down and function enables common memory to be shared
reusable-component approaches, with improved by multiple plant controllers and a common
online maintenance capability. POL language process I/O database to be established when
is supported to maintain upward compatibility dataway remote I/O (DRIO) is used. This al-
with applications developed for previous con- lows applications to be moved, configuration
trol systems. of 1:N backup systems and use of online simu-
Hardware reliability has been improved through lations to shorten program development time.
the use of custom LSIs, which lower component Ethernet communications are implemented
Key
ICS Industrial computer system OPS750 high-performance
OPU Operation unit operator console
DRIO Dataway remote I/O
MELSECNET
Ethernet
Ethernet
Operator Operator
OPU console OPU console
MELSUCSES
engineering
tool
*Mitsunori Hirayama and Nobuchika Furusawa are with the Power & Industrial Systems Center.
June 1997 15
TECHNICAL REPORTS
Transmission media Optical fiber cable 10BASE-5/2/T selectable Optical fiber cable
Cyclic communi-
1.7ms/1kw and 30ms/32kw 4,096 bits and 4,096 words
cation
using the socket interface of the TCP/IP proto- The operator console consists of an IBM PC
col. Two communication systems are provided: AT compatible personal computer fitted with
a general-purpose N:N system and a special- an Ethernet card and running the Windows
ized system for the operator console. The pro- operating system. Use of de facto standards al-
tocol processing is performed by a dedicated lows the console to utilize the latest advances
board that reduces the load on the main proces- in hardware and software. A touch-screen is also
sors. supported for implementing simplified operat-
MELSEC-NET supports connection to the op- ing environments.
eration units (OPU) and general-purpose pro- The operation panel of the OPU has been
grammable controllers. automated and standardized by combining a
Table 1 lists the MELPLAC-750 network sheet keyboard and a programmable controller
specifications. (Fig. 2). The arrangement of switches and lamps
can be easily altered, and name labels changed
Operator Console Features as necessary to meet individual application re-
The OPS750 operator console is a high-perfor-
mance unit designed specifically to support
control of electrical, instrumentation and com- Four-digit 7-segment LED
displays (4)
puter control systems. The console has hierar- MELSEC-NET
chical monitoring functions that make it easy
to locate irregularities in computers, control-
lers and other equipment installed on the inte-
grated control network. The console can be
operated without programming through the use Sheet keys with LEDs (32)
of standard functions such as alarms, trend
graphs and instrument displays, and a graph/
table builder. Fig. 2 The operation unit.
Engineering Features
A programming panel designed to be compact
and portable supports POL and DDC program
development and maintenance. This versatile
unit can be used to enter software offline, and
to perform a final online setup on the shop floor.
MELSUCSES, the corporations comprehen-
sive engineering system, provides for unified
management of data from many kinds of plants,
and supports high-level symbolic description of
operation schedules using the Macro Control
Diagram (MCD) language. The system supports
the entire software life cycle. It conducts syn-
tax checking of operation plans, automatic soft-
ware generation and transfer, monitoring and
hard-copy output of settings data for the inte-
grated control network and software. It also
maintains a database of specifications and main-
tenance data for plant electrical equipment.
Both tools support concurrent engineering
architectures in which multiple units are linked
to a single controller.
June 1997 17
TECHNICAL REPORTS
System Configuration
Fig. 1 shows the system hardware, which in- Fig. 1 Hardware configuration.
cludes an online process control computer and
an offline data analysis and simulation com-
puter joined by a Ethernet LAN. The process Control model
analysis support
control computer acquires process control data system Graphic analysis tool
and transfers it periodically to the offline com-
puter, which can analyze the data without af- Offline simulators
Control system
fecting the process control computer. simulator
Actual
Fig. 2 shows the system software, which con- database Physical model
sists of a graphic analysis tool and offline simula- simulator
tor functions. The graphic analysis tool extracts
data from the process control history database and
rapidly converts this data to graphic form for vi-
sual inspection. The offline simulator simulates
Fig. 2 Software configuration.
the behavior of the process using two models. The
control system simulator simulates the predic-
tive digital feed-forward control and feedback con- Learning
trol of the online control system. The physical calculation
Initial setup Revised Feedback
model simulator uses mathematical models of control setup control control
the controlled objects to simulate their behavior
for predictive purposes.
Coiling
Coiling Temperature Control Analysis Finishing mill Finishing Laminar bank pyrometer
mill delivery Runout table Coiler
Support System pyrometer
We will now describe the use of the control Fig. 3 Coiling temperature control system.
model analysis support system to analyze coil-
ing temperature control in a hot-rolling mill. The process control computer for these func-
Fig. 3 shows the line equipment between the tions transfers data via a LAN to an offline com-
finishing mill and the coiler, and a general dia- puter which carries the cooling temperature
gram of the online process control system. The graphic analysis tool and the coiling tempera-
process control system consists of initial setup ture control simulation functions.
prediction control, revised setup prediction con- The cooling temperature graphic analysis tool
trol and feedback control. It controls the pour- represents data samples taken over the entire
ing timing of the laminar bank at the runout coil length as an analog chart. The user enters
table and controls the cooling of the hot strip to date, product number, product size, accuracy
provide the specified coiling temperature. and other parameters to define the dataset, and
the corresponding data is extracted from the
*Naoki Shimoda and Yoshinori Wakamiya are with the Power & Industrial Systems Center.
1000
800
700
600
Coiling
temperature
500
1200
0
1200
database and converted to graphic output to ber, product size, target product coiling tempera-
identify insufficient cooling and other control ture, etc., causing the system to reference the da-
inadequacies (Fig. 4). tabase for the corresponding dataset, conduct a
The coiling temperature control simulator simulation based on this dataset, and display the
function simulates the control logic of the actual and simulated data together. The graphs
online control system including both the setup
prediction control that determines the switch-
Heat flux (kcal/m2.h)
750 9,000
ing pattern of laminar pouring control at the
Coiling temperature (C)
runout table and the feedback control activity 700 Actual heat flux Simulated heat flux 3,000
based on the actual coiling temperature mea- Simulated coiling temperature
surement data. The physical model simulator 650 6,000
Actual coiling
uses mathematical models for the thermal ef- temperature
fects of water and air cooling to simulate the 600
cooling behavior of strip on the runout table.
The heat flux coefficient for water cooling is 550
June 1997 19
TECHNICAL REPORTS
This article introduces welding equipment for ness of the parent material. Fig. 1 compares the
modern steel processing lines: a flash welder ratio of the finished zone to the thickness of
with a shear, a mash-seam welder capable of the parent material for current and previous
welding seams nearly as thick as the parent welders.
material and special-purpose laser-beam weld- A variety of equipment is available for auto-
ers. The article also describes use of induction mated operation. A parallel adjustment unit
heaters to produce high-quality steel pipe and with a clamp system replaces a conventional
use of computer magnetic-field analysis in in- side guide for better control of the welding angle.
duction heater design. An automatic height adjustment for the lower
electrode avoids the possibility for poor seams
Flash Welders associated with manual adjustment. An on-line
Recent flash welders often include a shear, automated electrode-forming unit can be used
unlike previous gauge bars. The corporations to prevent quality lapses due to electrode shape
newest flash welder, Model NMW-C, has a ro- irregularities, and an on-line automated weld-
tary shear that can cut strip head and tail quality inspection unit is also available.
simultaneously at the rate of 60m/min, weld at
the cut and trim the bead. Strips are butted pre- Laser-Beam Welders
cisely and automatically in preparation for weld- Laser-beam welders are used for specialty weld-
ing, and handling time is reduced. An original ing applications requiring that the heat-affected
oil-dipped welding technique is available for zone be as small as possible. As shown in Fig.
specialty welding. Oil dipping improves weld 2, a laser-beam welder welds faster than a metal-
quality by excluding oxides from the welding active gas (MAG) welder, which is also a fu-
seam when oil combustion consumes oxygen sion-type welder. The downtime of the input
under the cover. Post annealing can be con- section is reduced because welds almost as thick
ducted using the flash welder power-supply with as the parent material allow a reduction in pro-
the workpiece in position after welding and cessing time. Longer welding and handling
trimming. times compared to flash or mash-seam welders
confine applications primarily to specialty weld-
Mash-Seam Welder ing. Mitsubishi laser-beam welders are supplied
A key issue in mash-seam welder design is that as complete solutions, including a mechanism
the thickness of the weld approach the thick- to ensure a precise butt gap and original oscilla-
tor technology.
Improved
170 Original
6 10kW laser-beam welder
160
5kW laser-beam welder
Welding speed (m/min)
5
150 MAG welder
140 4
130 3
120 2
110
1
100
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 0
Parent material thickness (mm) 1 2 3 4 5 6
Parent material thickness (mm)
*Toshinobu Eguchi and Keiji Sodeno are with the Itami Works.
June 1997 21
TECHNICAL REPORTS
Fig. 3 Advantages and applications of induction heaters for steel pipe processing.
of steel pipe in Japan by application: heat treat- which has the disadvantages of large space re-
ment, hot forming and surface treatment (Fig. 3). quirement, generation of oxide scale during
extended heating, poor controllability, and long
S OLID SOLUTION TREATMENT FOR STAINLESS furnace startup and shutdown times. Induction
STEEL PIPE. In general, this process is conducted heating, by contrast, requires lower capital in-
by heating the pipe to the treatment tempera- vestment, and where energy transmission effi-
ture in a furnace and then removing the pipe ciency is an issue, the induction heater can be
and rapidly cooling it by water quenching, as placed at the exit of a heating furnace to reduce
specified in the JIS standards. Mitsubishi Elec- electricity consumption.
tric has delivered lines that take the stainless
skelp formed into pipe and perform welding, CONTINUOUS PREHEATING FOR ZINC PLATING.
forming, induction heating, temperature- Formed pipe intended for molten zinc plating
keeping, quenching, lengthwise forming and is preheated prior to immersion in the plating
cutting in a continuous process with online con- tank. The preheat prevents a drop in tank tem-
trol. The temperature-keeping step, which pro- perature, improves plating adhesion and results
vides time for crystal grain diffusion, can be in a stronger plated layer. Induction heating al-
shortened by raising the temperature by 50C lows preheating in a nitrogen atmosphere that
over the conventional treatment temperature. prevents surface oxidation. In addition, the rate
of heating can be adjusted to match the line
HEATING FOR CONTINUOUS REDUCTION. The line speed, ensuring a uniform workpiece tempera-
changes required to produce different pipe prod- ture for introduction to the plating tank.
ucts generally require time-consuming process
adjustments to suit the type of steel and pipe New Technologies for Magnetic-Field and
dimensions. A faster, more continuous approach Thermal Analysis
is to start with a limited selection of skelp Recent advances in computer hardware and
materials, form these into pipe and shrink the software have made it possible to evaluate com-
diameter of this parent material to the required plicated magnetic-field and thermal models
dimensions while the pipe is hot. The parent with a high degree of accuracy. This technol-
pipe is usually heated by a combustion furnace, ogy has been applied to induction heater design
June 1997 23
R & D PROGRESS REPORT
R&D PROGRESS REPORT
A Novel
Regenerative Snubber Main circuit
circuit circuit
LA1
Regenerative DC/DC1
CO1
DR1
DS1
CS1
GTO1 DF1
Snubber Circuit
E
CF1 CS3 DC1
DR3 LA3
DC/DC3
DS2 DC2
GTO2
DF2
GTO Inverters E
DC/DC4 CO2
DR2
LA2
CS2 GTO3 DF3
*Hideo Okayama and Taichiro Tsuchiya are with the Industrial Electronics & Systems Laboratory.
dt GTO2 2CS
400
GTO2 (n=20)
The load current is commutated via LA4 to
200
DF4 to DF3, as the GTO2 turn-off is com-
pleted. All of the energy stored in the snubber
0
circuits is recovered through the corresponding 0 1,000 2,000 3,000 4,000 5,000 6,000
clamping capacitors. Load current (A)
Fig. 3 Voltage rate-of-rise characteristics of GTO
Switching Duty thyristors for CO = n CS.
We will start by comparing the current rate-of-
rise during turn-on of the outer and inner GTO
thyristors. Fig. 2 shows the current rate-of-rise thyristors is dependent on the capacitance.
vs. time after thyristor turn-on at different If the capacitance of the clamping capacitor
inductance values for LA1 and LA2. The DC is an integer multiple (n) of the snubber ca-
linlink voltage is 2E = 6,000V and the induc- pacitance, the voltage rate-of-rise of the inner
tance of anode reactor LA1 is 13H. The cur- GTO thyristors is given by Eq. 6. From Fig. 3,
rent rate-of-rise for the outer GTO thyristors is for n values near 20, the inner GTO thyristor
constant over the interval that the load current rate-of-rise is about half that of the outer GTO
is being commutated. The current rate-of-rise thyristors.
for the inner GTO thyristors is steeper than for
dv = n . ................. (Eq. 6)
dt GTO2 1 + 1 + n CS
the outer GTO thyristors. At n=1, when the
inductances of LA2 and LA1 are the same, the
current rate-of-rise of the inner GTO thyristors
Total Commutation Time
reaches double that of the outer GTO thyris-
We define the total commutation time as the
tors immediately after turn-on. This steepness
time from the start of switching until all the
is due to the discharge current of the inner
energy stored in the snubber circuits has been
snubber capacitors, and declines over time.
collected by the corresponding clamping ca-
When n = 2, the ratio of current rate-of-rise for
pacitors. Figs. 4 and 5 show the total commu-
inner to outer GTO thyristors drops to 1.5.
tation time as a function of the outer GTO
Next, we will compare the voltage rate-of-
thyristor load current and clamping capacitor
rise of the outer and inner GTO thyristors
voltage. The total commutation time charac-
during turn-off. Fig. 3 shows voltage rate-of-
teristics of the inner GTO thyristors (not
rise vs. load current characteristics with 6F
shown) are similar. The following circuit con-
snubber capacitors.
stants apply:
Though the voltage rate-of-rise of the outer
GTO thyristors is independent of clamping
capacitor capacitance, that of the inner GTO
Total commutation time (s)
500
GTO2 (n=1)
400
Current rate-of-rise (A/s)
GTO2 (n=2)
150
300
GTO1 100 330
200 50 480
1,200 630
2,700 780
100 Loa
d cu 4,200
rren 5,700
t (A
0
)
0 5 10 15 20
Time (s)
Fig. 2 Current rate-of-rise characteristics of GTO Fig. 4 Total commutation time at turn-on of outer
thyristors for LA2 = n LA1. GTO thyristors.
June 1997 25
R&D PROGRESS REPORT
Width and length profile meter Crop profile meter Crop profile meter
Plate
*Katsuya Ueki and Masayuki Sugiyama are with the Power & Industrial Systems Center.
June 1997 27
TECHNICAL HIGHLIGHTS
S=
b
1 + dy dx .......... (Eq. 3) Fig. 4 Block diagram of crop profile meter.
a dx able for use. Two-dimensional pro- and noise components are removed,
file measurement is needed to de- yielding a two-dimensional crop
Substituting for the elongation rate termine effective sheet length and profile.
yields the following. the optimum cutting positions. A Use of a high-intensity blue LED
crop profile meter can be used for allows the backlight system to be
b 2
1 dy dx two types of measurement meth- used anywhere on the line, regard-
2 adx
ods: an active measurement system less of the steel plate temperature.
=
b
dx .................. (Eq. 4)
a
using a backlight or a passive mea- This wavelength is significantly
surement system using the steel shorter than the central emission
plates radiant energy, depending on wavelength of even hot steel plate,
By integrating the height difference the steel plate temperature. yielding an excellent S/N ratio.
detected by the twin beams, the vi- Fig. 4 illustrates an active system
bration components can be elimi- using a backlight. The field of view State-of-the-art noncontact mea-
nated, giving us the elongation rate. of a linear-array CCD camera is ori- surement systems, such as those
Fig. 3 shows a block diagram of a ented across the steel plate width. described here, can be tied into a
flatness measurement system using At fixed increments along the steel mills control system, making it
multiple twin-beam laser displace- plates length, the cameras video possible to produce steel plate with
ment sensors positioned across the output is passed through an ana- greater accuracy and dimensional
width of the steel plate. logue-to-digital converter (ADC) uniformity.
and stored in memory. The light
Crop Profile Meter from the backlight is interrupted by
The head and tail ends of the steel the steel plate, creating a silhouette
plate exiting the finishing mill have image at each line of measurement.
an irregular profile and are unsuit- This image information is processed
Tracking Mechanism
Fig. 2 shows a diagram of the data-
base systems tracking mechanism. Fig. 2 The tracking mechanism.
*Hideyuki Takada and Joji Ido are with the Industrial Electronics & Systems Laboratory.
June 1997 29
TECHNICAL HIGHLIGHTS
June 1997 31
NEW TECHNOLOGIES
A Mediation Technology for the Integration of Heterogeneous Infor-mation
Resources
Mitsubishi Electric has developed
middleware technology for the inte-
gration of heterogeneous information
resources. This technology enables
the integration of existing information
resources distributed over networks,
including relational, object-oriented,
image, flat file and other types of
databases as well as application
programs such as simulators and AI
systems.
As the illustration shows, a module
called a wrapper is established for
each information resource. The wrap-
per translates between the data
architecture of the specific informa-
tion resource and a common system
data architecture. Application pro-
grams send an information referenc-
ing request to a module called a
mediator. The mediator refers to a
mediator specification and automati- Mediation architecture
cally gathers the requested informa-
tion from the appropriate resources alone systems for monitoring, control information system can be readily
via the wrappers and integrates this and production management, allow- expanded.
information, which it returns to the ing easy implementation of distri- The middleware provides a critical
application that issued the original buted information systems. New missing function in network program-
referencing request. resources can be easily added by ming: the ability to integrate existing
In steel plants, this technology en- creating a wrapper and updating the databases. Implementation is simple,
ables the integration of current stand- mediator specifications, so that the cost-effective and practical.