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
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 Slide 2
Joy Global ABB Success Story Bild Canada Slide 3
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 size R8i for all drives and supply Special Firmware for dynamic load requirements 20 years life cycle requirement In operation 75 AC Drives for new Shovels and 8 for retrofit 2 x Premium Supplier Award from Joy Global Proven Mining Drive solution for extreme conditions Slide 4
158.00549 159.75456 161.65179 163.54356 165.41656 167.28468 169.15477 171.04047 172.78848 174.63992 176.505 178.34305 180.18873 182.03048 183.7785 185.64566 187.5214 189.3985 191.27347 193.1543 195.01837 196.78312 198.61219 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 3500 3000 2500 2000 1500 1000 500 0-500 -1000-1500 -2000-2500 -3000-3500 -4000 Hoist rpm Hoist kw Hoist Nm 25000 20000 15000 10000 5000 0-5000 -10000-15000 -20000-25000 Slide 5
Physics and mining environment IGBT-Modules EconoPack FS450R12KE3 Current: 450A Peak: 900A Voltage: 690V Operation temp.: 125 C Peak temp.: 150 C Slide 6
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 Constant torque operation with current cycling Continuous operation 24h Compound material stressed by different nature Physics: mechan, thermal, electrical, chemical, radiation Slide 7
Analysis and continuous improvements Supplier: Infineon EconoPack TM FS450R17KE3 Transitor +Diode 3 phase module Transistor and Diode chip elements are connected with bond wires Principles of expanded bond wires New is changed bonding wire design and soldering Result: Bonding wire is flexible to withstand temp cycles and vibration requirements Slide 8
Analysis and continuous improvements EconoPack TM FS450R17KE3 96 power elements for 1 shovel 576 IGBTs per machine Heatsink after dry-out of thermal interface material Principles of Thermal Interface Material (TIM) New TIM as phase shift material, with stencil and specific pattern Result: no dry out Slide 9
Quality process ABB 4Q Process Improvements Steps to be successful 4Q Process Q1 Various on-site measurements and site surveys Sample analysis by 3 rd parties with expert knowledge Q2 Providing the root cause analysis (RCA) Evaluation the RCA with supplier of power components Q3 Identify measures to improve the drive system Implement features in production and existing fleet Q4 Review of failure rate, which became <2% for over 2100 R8i Analysis of improvements after operating over time Q1 - Measure Define opportunity Investigate to understand the current state in detail. - Goal is to identify and use those process Outputs, metrics that can help to understand when, how and what problem occurred. - Or what additional measures do you need to help identify the problem root cause? Q4 - Sustain Maintain the improvements by standardizing the work methods or processes. - Goal is to change the process to the new solution piloted in Q3. - Gains will be sustained by people working to the new process. New metrics may need to be monitored back in Q1 to - Close the continuous improvement loop. Q2 - Analyze Identify and confirm root causes of the problem. - Goal is to find the real root causes for the problem. Eliminating the root causes prevents the problem from occurring again. - Good root cause analysis is the key to success in any 4Q project. Q3 - Improve Develop, pilot, and implement solutions that eliminate root causes. - Goal: create and execute pilot actions that will eliminate the root causes. - Test the results and decide if the results are good enough to move forward to next quadrant, - Make the changes permanent Slide 10
Analysis and continuous improvements Test stand to check each IGBT before release to installation Visual inspection Electrical test Output waveform scope check New device for thermal grease application Precisely given amount in specified pattern New drying furnace to dry out thermal grease according specification Precisely laid and dried Improved heat flow achieved Internally tested for 100000+ cycles without any leakage signs Slide 11
Analysis and continuous improvements 1000 CROWD Temp&Current OLD SOFT 140 ACS800 Drives Firmware DTC (Direct Torque Control) Change system control program Analysis of load cycle and high torque requirements Changing switching frequency at low speed Parameter setting to limit switching frequency below 30% of nominal speed Default value switching frequency changed from 2kHz to 1,4kHz Low limit of switching frequency reduced from 1,4 khz to 1kHz 800 600 400 200 0 1000 800 ACS800 Temp [C] Current [A] CROWD Temp&Current NEW SOFT 120 100 80 60 40 TEMP 100 80 Result: Reduction of peak temperature by 40% 600 60 400 40 200 20 ACS800 Live time improvement 10+ years 0 0 Current [A] ACS800 Temp [C] Slide 12
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 10 years life time within 16 weeks by higher temp. range and increased number of load cycles New equipment on ABB Drives test lab with 2D & 3D x-ray system, Electron Microscope, ultrasonic analyzer Result: MTBF R8i module = 93 Y (ACS800), 210 Y (ACS880) ABB is providing an extensive product test process Slide 13
Summary Global fleet of Electric Shovels AC Number of IGBTs 7000+ Failure rate below 2% Product life cycle 12 years Improved lifetime by reduced thermal cycling Ongoing reliability testing for Drives modules Established AC Drives Technology in extreme environment NA 33 SA 34 MEA 7 EU 1 APA 8 Slide 14