This paper substantiates why it is necessary to limit the dynamic loads in stand shafts when closing angular gaps. The paper is a feasibility study of a concept developed specifically to limit each of the factors that affect amplitude of the dynamic torque; limitations applied are determined on a case-by-case basis. The research team studied the components of elastic torque in a dual-mass electromechanical system of Mill 5000 caused by vibrations arising from the elasticity of transmission as well as from the vibrations caused by elastic collision itself. It is shown that the lowest possible pre-acceleration is necessary for decreasing the dynamic coefficient at a near-nominal load torque. A principle of limiting dynamic loads when closing an angular gap is proposed, which implies collecting tachograms of an electric drive subjected to positive or negative acceleration before and after the fed metal is captured. The research team has developed drive control principles to implement this approach. The recommendation is to upgrade the electric drives of the reversing stand in Mill 5000.
The existing publications on the analysis of power quality indicators in modern electric power supply systems are void of a comprehensive approach to improving these indicators in power systems by implementing multipulse connections. To the authors’ knowledge, this paper is the first to analyze current harmonic distortions in an 18-pulse connection of three-level active front-ends (AFE) featuring a programmed PWM. Raw data were obtained from, and current quality was analyzed for the power circuit of the main electric drive actuating the rolls in the rolling stand of a plate mill. The key feature of such circuitry is that the synchronous motor of each work roll is connected to the grid with an 18-pulse connection that uses three phase-shift transformers, where the phase shifts are 0° (delta/delta), 20° (delta/polygon) and −20° (delta/polygon). The circuitry connects three frequency converters (FC) with the AFEs in parallel. Phase-shift transformers were found to periodically overheat in the process. When overheating occurred, a programmed PWM voltage waveform was applied where harmonics 17 and 19 were eliminated. The goal and objectives were to analyze why the transformer would overheat and to find out how the issue could be addressed. The authors developed a simulation model of the research object in order to assess power quality parameters. Simulation results obtained in Matlab/Simulink were used to estimate the total harmonic distortions (THD) and individual harmonic factors for up to the 50th secondary transformer winding and grid harmonic with four different programmed AFE PWM voltage waveforms. The results helped find the best such waveform to prevent phase-shift transformers from overheating; one with harmonics 5, 7, 17 and 19 eliminated. The experimental and mathematical modeling results in the paper were confirmed by positive effects after industrial implementation of the system. Research performed directly on the operating equipment has been classified by the company and is not publicly available. These results are highly versatile and could be used in similar research on other circuitries to ensure the electromagnetic compatibility of nonlinear power-consuming devices.
We herein present a mathematical model of hot rolling temperature parameters that factors in how the strip temperature changes in the rolling stand and in the inter-stand gap as well as when metal is transported along the mill train. It factors in the temperature losses caused by thermal radiation and the convective transfer of heat from and to the environment, occurring in the inter-stand gap; temperature losses are also caused by the contact heat transfer from and to the rollers as well as by the heating of the strip in the plastic deformation site. This paper presents the results of using this model to make calculations for a wide-strip hot rolling mill. It illustrates how the model could be used in the algorithm for building a state-of-the-art virtual training simulator.
The authors propose a technique for reactive power compensation using a powerful regenerative controlled-speed synchronous motor drive (SMD) based on a three-level (3L) neutral point clamped (NPC) active front-end rectifier (AFE) and a voltage source inverter (VSI). The review of technical solutions for reactive power compensation showed that the limitations on the transmitted reactive power in the system under consideration still have not been studied. The paper provides a mathematical description and proposes synthesis-friendly block diagrams of the mathematical 3L-NPC-AFE-VSI and SMD models. The developed models allow defining the instantaneous values of the total 3L-NPC-AFE power consumed from the grid depending on the SMD load diagram. It is noted that the 3L-NPC-AFE-VSI-SMD system is designed without considering the opportunities for reactive power generation. It was determined that the limit value of reactive power generated by a 3L-NPC-AFE depends on the DC link voltage, the grid current consumption and the modulation index. The possibility of reactive power compensation by the SMD system through a 3L-NPC-AFE was experimentally tested on the main drive of a metal plate hot rolling mill. The analysis of the results obtained showed that during the breakdown, an SMD can generate reactive power equal to 16% of the total rated power using a 3L-NPC-AFE at a rated DC link voltage and without overcurrent. It was shown that generating reactive power is expedient in low-load SMD operation modes or at idle. Research in this area is promising due to the widespread use of high-power SMD based on a 3L-NPC-AFE-VSI and the tightening of requirements for energy saving and efficiency and supply voltage quality. The proposed reactive power control technique can be used as part of an industrial smart grid.
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