Motion Control & Drives


Steely-eyed control: Control Techniques drives continuous casters at Corus

July 2008 Motion Control & Drives

Unidrive SP AC drives feature on the latest continuous slab caster, at Corus steelworks in Port Talbot, South Wales, controlling critical operations at the head of the production line.

Continuous Caster 3 (CC3) is a completely new operation, aimed to increase the output of the Welsh plant by 25%. Previous major contracts for Control Techniques had been upgrades, re-utilising existing DC drives, so the drive of choice was Mentor II. Now, looking to the potential benefits of reduced motor maintenance from a switch to AC, and the reduced downtime that this implies, the project team grasped the opportunity for increased efficiency. Again stating a preference for Control Techniques on the CC3 project, Corus elected for the Unidrive SP.

"This is our first real experience with Control Techniques' Unidrive SP AC drives," says Corus Concast engineer, Roger Morgan. "We have found them to be very reliable, easy to use and easy to configure. The whole approach to this project has been a move forward in technology, with digital interfaces and greatly reduced wiring."

The proposition was based on the latest AC drive and motor technology from Emerson Industrial Automation companies' Control Techniques and Leroy Somer. All the motors ensured totally enclosed protection for improved reliability and less downtime. The scope incorporated two new AC Drive Motor Control Centres, employing some 60 AC Unidrive SP variable speed drives and Leroy Somer AC motors. The drives provided a much improved load sharing, a more consistent casting speed, shorter rethread times, and a big boost in reliability. All these features were a pre-requisite for greater productivity and finished steel quality.

Key to the successful operation of the plant was the intelligent load sharing system, pre-programmed into each Unidrive SP drive, using the on-board facility of the plug-in application modules. The success of this software, with its benefits of reduced wear and more consistent casting speed, is very evident in the motor current trends. Rethread times are also much faster, with any limitations being factors other than the drive electronics.

The new AC motors manufactured by Leroy Somer, were each fitted with digital encoders and brakes on the vertical part of the caster. The drive control included on-board intelligence and specific application software, part of which included closed loop to open loop changeover in the event of a feedback device failure, thus ensuring the caster continues to run.

“The whole system is more modular,” explains Roger Morgan. “The intelligence in the system is distributed rather than central, and this means that just one Unidrive SP Inverter is designated as the master and communicates with the plant PLC. This Master then communicates in turn via CTNet with all the other strand drives, keeping them digitally synchronised. For reasons of dual redundancy, 'Automatic Seamless Master Transfer' – passes Master control to the next drive in line, in the event of failure. This means that, if necessary, the line could be run manually. It is now much more flexible and reflects many of the lessons we have learnt over many years of steel-making. The evidence of its success is reflected in the 30% increase in strand speed and the reduced turn-around times.

“We are very pleased with the results of this major project,” continues Roger Morgan. “The after sales support we receive from Control Techniques has been excellent and indeed our long-standing experience of good support over several major schemes was a factor in Control Techniques being chosen for this project.”

For more information contact Bill Tedd, Control Techniques, +27 (0)11 462 1740, [email protected], www.controltechniques.com



Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Turbomachinery controls: the call of duty
Schneider Electric South Africa Motion Control & Drives
There’s a lot to be said about the unsung heroes of this world; those men, women and machines that deliver such important functions, often overlooked and recognised. One such machine is turbomachinery, and while the name does sound quite obvious to the layman, its rich history and daily functions are not.

Read more...
More movement in the market
Motion Control & Drives
Aerotech aims to revolutionise the market for precision motion and machine controls with an intuitive control platform.

Read more...
Tapered roller bearings for wind turbines
Motion Control & Drives
A leading European manufacturer of wind turbines will use NSK’s tapered roller bearings with high load capacity in the gearboxes of its 15 MW class offshore wind turbines. The decision to specify the next-generation NSK roller bearings hinged on several key factors.

Read more...
Efficient maintenance counts
Bearing Man Group t/a BMG Motion Control & Drives
BMG’s total plant management solutions encompass a technical advisory service for maintenance programmes that includes correct chain and sprocket selection, which is a critical factor in any power transmission system.

Read more...
Automating drive systems for efficiency and reliability
SEW-EURODRIVE Motion Control & Drives
Already in use by leading global manufacturers in South Africa, SEW-EURODRIVE’s innovative MOVI-C modular automation system will bring a new level of flexibility, integration and efficiency to a wide range of sectors.

Read more...
Monitoring vibration allows for equipment longevity
Iritron Motion Control & Drives
Unscheduled downtime and maintenance on machines is often a source of frustration for many companies active in industrial manufacturing as it results in loss of process and productivity, which in turn equates to loss of revenue.

Read more...
Driving innovation in robotics and automation
Yaskawa Southern Africa Motion Control & Drives
Maintaining a competitive edge in a rapidly changing industrial landscape means embracing new technologies and adapting to evolving market demands. Yaskawa Southern Africa has positioned itself as a leader in robotics and automation, particularly in areas such as palletising, materials handling and advanced manufacturing

Read more...
Regular maintenance of cutting fluids is essential to maintain quality
Motion Control & Drives
Regular cleaning and maintenance of cutting fluid systems significantly enhances overall efficiency by extending the life of the cutting fluids, reducing downtime and improving the quality of the end products.

Read more...
Tough chain and induction hardened sprockets
Bearing Man Group t/a BMG Motion Control & Drives
BMG’s Tsubaki Titan chain series offers significant improvements in wear life, particularly in demanding applications like abrasive and dusty conditions.

Read more...
Rethinking common approaches to wire rope lubrication
Motion Control & Drives
Wire ropes are hard-working components in many different applications, from mines to lifts, ports, construction sites and drainage systems. Correct lubrication of wire ropes is absolutely critical because wire ropes are more than just cables, they are intricate machines composed of interdependent parts in constant motion.

Read more...