GOVERNMENT ENGINEERING COLLEGE THRISSUR

2011 INDUSTRIAL TRAINING REPORT

EDDY CURRENT CONTROLS (INDIA) LTD. CHALAKUDY

Submitted by APARNA MENON K DEEPA M S GAYATHRY DAYANANDAN JERIN JAMES

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

Government Engineering College, Thrissur

Department of Electrical & Electronics Engineering

2011
CERTIFICATE Certified that this is the report of the industrial training at EDDY CURRENT CONTROLS (INDIA) LTD., CHALAKUDY Done by APARNA MENON K ETAJEEE017
Of second year B. Tech, Electrical And Electronics Engineering in partial fulfillment of the requirement for the award of the degree of Bachelor of Technology in Electrical & Electronics Engineering under the University of Calicut during the year 2011.

Group Advisor

Prof. Uma Syamkumar Assistant Professor Dept of Electrical & Electronics Engg. Govt. Engineering College,Thrissur

Head of the Department Dept of Electrical & Electronics Engg. Govt. Engineering College,Thrissur

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ACKNOWLEDGEMENT

It is my proud privilege to express my sincere gratitude and deep indebtedness to the people who accompanied me to complete this industrial training successfully.

I am deeply grateful to our principal Dr. Vijayakumar K for providing all the facilities.

I am indebted to the Head of the Department of Electrical & Electronics Engineering, for the encouragement and supervision.

I would like to express my gratitude to Prof. Uma Syamkumar, Group Advisor, Department of Electrical & Electronics Engineering, for her valuable advices and whole hearted co-operation.

I take this opportunity to thank Mr. Jose M.D., Mr. Rejiv Antony and other staff from Eddy Current Controls (India) Ltd., who helped us at the industrial training period through supervision and comments.

I express my sincere gratitude to all the faculties of the Department of Electrical & Electronics Engineering, whose encouragement and support were indispensable.

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TABLE OF CONTENTS

LIST OF FIGURES LIST OF SYMBOLS LIST OF ABBREVIATIONS

v vi vii

1. INTRODUCTION 2. COMPANY BACKGROUND 3. TRAINING 4. PRODUCTS FROM ECC(I)LTD. 5. APPLICATIONS 6. CONCLUSION REFERENCES

1 2 4 11 14 15 16

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LIST OF FIGURES

Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.

Dynodrive Block diagram of working of dynodrive Block diagram of regulator Block diagram of MOSFET based DC drive Block diagram of MOSFET bridge circuit Switched Reluctance Motor Platform truck

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LIST OF SYMBOLS

V A rpm W kW Hz kmph

: : : : : : :

Volt Ampere rotations per minute Watt kilowatt Hertz kilometre per hour

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LIST OF ABBREVIATIONS

AC DC UPS HSAT VFD MOSFET PWM

: : : : : : :

Alternating Current Direct Current Uninterrupted Power Supply Helicopter Securing And Traversing Variable Frequency Drive Metal Oxide Semiconductor Field Effect Transistor Pulse Width Modulation

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1. INTRODUCTION
Dynodrive Variable Speed Drives based on the Eddy current principle. It is most suited for speed control in the dusty and slurry industrial environments like cement industry, coal feeders etc. Dynodrive can be configured to operate in closed loop speed regulation using simple electronic regulator. Eddy Current Controls (India) Ltd. also manufactures other special controllers for dynodrive to interface the system to external digital control stations.

Switched Reluctance Drive is an innovative high efficient drive system suitable for traction variable speed applications. This new drive system has the advantage of AC and DC drives and overcome their disadvantages namely brush maintenance in DC drives and low starting torque AC drives.

They are offering a wide range of Electrically Operated Platform Trucks. On the movement of goods-to be more specific ensures a smooth flow of goods in the production unit. Filetriever - Office Automation is fully automatic and innovative filing system for maximum safety, increased productivity and next generation features.

Eddy High Efficiency Batteries are specially designed for UPS/Inverter applications to suit deep and heavy load requirements. Ceramic Aqua Trap Vent Plugs are provided to avoid evaporation of water from cells where as the porous structure traps acid vapors, allowing only gases to go out.

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2. COMPANY BACKGROUND

Established in the year 1971, as a Public Limited Company, Eddy Current Controls India Limited (ECCIL) is the pioneer in manufacturing Eddy Current Variable Speed Drives (Dynodrive) and related control systems in India. Eddy Current controls (India) Ltd. began the manufacture of dynodrive or variable speed drives in 1967, in collaboration with Yaskawa Electric Mfg. Co. Ltd., Japan. At present they are having more than 40,000 Dynodrive installations across India. Eddy ventured into the production of electric vehicles in 1990. Eddy Current controls (India) Ltd. began the manufacture of dynodrive or variable speed drives in 1967, in collaboration with Yaskawa Electric Mfg. Co. Ltd., Japan.

Later they started manufacturing electric material handling equipments and related controls. It is an all-India customer base which includes giants of the public and private sectors. They supply 60% of the domestic markets demand for Variable Speed Drives. They also export to a number of clients in the Gulf countries, African countries and Europe. Its research and development unit is equipped with the latest testing, analyzing and measuring instruments along with other sophisticated scientific equipment.

Switched Reluctance Drives developed under a project granted by Department of Electronic and Technology Development Board, Govt. of India won the national award for the best product in the year 2000.

Drives and controls for Helicopter Securing and Traversing (HSAT) System. This was developed as an import substitute for use in Naval Warships.

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Gravimetric Feeder Drives and Controls. This was developed jointly with Bharat Heavy Electricals Limited for replacing the old drives used in Thermal Power Stations.

India's first indigenously developed electric car "LOVE BIRD ". Love Bird which runs on rechargeable batteries is the cheapest alternative available against conventional fuel driven vehicles.

Eddy Current Clutches for driving the radiator cooling fans used in diesel locos. This was developed for DLW, Varanasi and is certified by RDSO.

Drives and controls for shutters used in Dams and Canals. This was developed for Sardar Sarovar Narmada Nigam Limited for the Sardar Sarovar Project.

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3. TRAINING

3.1.

DYNODRIVE

3.1.1. Variable Speed Drives Eddy Current Variable Speed Drives "Dynodrive" is the ideal solution for precise speed and torque control. Eddy Current controls (India) Ltd. began the manufacture of dynodrive or variable speed drives in 1967, in collaboration with Yaskawa Electric Mfg. Co. Ltd., Japan.

Figure 1. Dynodrive

Dynodrive is used to control speed of induction motors by frequency control method. Dynodrive variable speed drives are adjustable speed drive packages combining in a common frame, a TEFC flange mounted, 3 phase induction motor and a self ventilated eddy current clutch of a compatible rating, housed in a guarded enclosure. The range of Dynodrive variable speed drives covers all standard ratings,

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from 0.4 KW to 310 KW. Output speed is adjusted by controlling the excitation of the eddy current clutch by means of a closed loop technique with speed feedback. The automatic adjustment of the excitation current occurs at a low power level.

Consequently the control power is only a small fraction of the drive power. Manual / Automatic Control makes the Dynodrive much simpler for automation. They are used in thermal power stations, cement industry, plywood industry, and paper and sugar industries and in chemical and fertilizer industries. They are also used in volumetric, gravimetric, rotary air clock, screw, raw coal, pulverized coal, bagasse and table/pendent feeders, and spreaders/distributors, scrapers, kiln drive and slurry pumps. The dynodrives have lesser maintenance problems, but are inefficient at lower speeds.

Rating and specifications of electronic regulators: 1) Power supply 200/220 V (+10% - 15%) 50/60 2) Model 121 (up to 11 kW), 141( 15 kW and above) 3) Output circuit capacity 200W,400W 4) Output circuit current 2.5A, 5A 5) Output circuit voltage 80V DC 6) Output circuit connection of thyristor single phase, half wave rectifying connection, with freewheeling diode 7) Speed setting input 7.8 V DC

The advantages of Dynodrive: Ruggedness and reliability Wide range of speed control Flexibility of control function Speed holding accuracy Low power control Zero harmonics

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3.1.2. Principle The equation N=120f/P implies that for a 50 Hz supply frequency in a 4 pole system, speed attained would be 1500 rpm. And for a 2 pole system it would be 3000 rpm. Suppose that number of poles do not change, changing the frequency to 100 Hz, for a 4 pole system, we attain 3000 rpm. This becomes the basic principle of dynodrive, i.e. varying speed by frequency control. Standard torque is reduced. Maximum 1200 rpm is attainable on theoretical 1500 rpm. No direct coupling used. The motor has a drum and pole arrangement. The drum is coupled to the input shaft and the pole is attached to the output shaft. Speed feedback is implemented using a tachogenerator. (The excitation coil at 0-80V; Speed of output shaft from 0 to 1200 rpm). Output of tachogenerator is 0-30V AC. The rotor is a permanent magnet. The windings form the stator part. The drum rotates at standard 1500 rpm. 0.2 mm air gap is provided for pole. Magnetic field strength is increased and North-South poles change continuously. 10% of rated speed is the minimum value. Below that gear box has to be coupled with the output shaft. 1:10 reduction is possible with the gear box, i.e. up to 12 rpm. When speed is reduced 10 times, torque is increased 10 times. 400W to 300kW power is expected.

Figure 2. Block diagram of working of dynodrive

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Figure 3. Block diagram of regulator

3.2.

MOSFET Based DC Drive

The speed controller works by varying the average voltage sent to the motor. It could do this by simply adjusting the voltage sent to the motor, but this is quite inefficient to do. A better way is to switch the motor's supply on and off very quickly. If the switching is fast enough, the motor doesn't notice it, it only notices the average effect. When the switch is closed, the motor sees 12 Volts, and when it is open it sees 0 Volts. If the switch is open for the same amount of time as it is closed, the motor will see an average of 6 Volts, and will run more slowly accordingly. As the amount of time that the voltage is on increases compared with the amount of time that it is off, the average speed of the motor increases. This on-off switching is performed by power

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MOSFETs. A MOSFET (Metal (Metal-Oxide-Semiconductor Semiconductor Field Effect Transistor) is a device that can turn very large currents on and off under the control of a low signal level voltage. The time that it takes a motor to speed up and slow down under switching g conditions is dependent on the inertia of the rotor (basically how heavy it is), and how much friction and load torque there is. The graph below shows the speed of a motor that is being turned on and off fairly slowly. When the average speed is around 150, 0, it varies quite a bit. If the supply voltage is switched fast enough, it wont have time to change speed much, and the speed will be quite steady. This is the principle of switch mode speed control. Thus the speed is set by PWM Pulse Width Modulation.

Figure 4. 4 Block diagram of MOSFET based DC drive

Figure 5. 5 Block diagram of MOSFET bridge circuit

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3.3.

Variable Frequency Drives (VFD)

The dynodrives are very inefficient at lower speeds. The dynodrives also

require special attention and maintenance, because of its semi-open construction. The variable frequency drives (VFD) are more efficient at lower/all speeds also and require lesser maintenance, in comparison to the dynodrive. Regulators, as in fans, were used in DC drives. Now thyristors are being used.

3.4.

Switched Reluctance Drives

Electric machines can be divided into electromagnetic drives and variable

reluctance drives on the basis of how they produce torque. The switched reluctance SR Drive system comprises a simple brushless motor with a dedicated electronic controller. Torque is produced by the magnetic attraction of a steel rotor to stator electromagnets. No permanent magnets are needed, and the rotor carries no squirrel cage or windings. Switched reluctance drive is basically a DC motor. It offers above 90% efficiency. It has high starting torque. It has no commutator or brushes, therefore maintenance cost is less. It has got MOSFET at each phase. Torque and speed is less. SVES (Granted by Dept. of Electronics and Technology Development Board, Govt. of India), won the National Award for the Best Industrial Product in the year 2000. The machines which produce motion by using variable reluctance are named as Switched Reluctance Motors. Motion is produced as a result of variable reluctance in the gap between rotor and stator. Switched Reluctance Motor drives are controlled by synchronizing the energization of the motor phase with the rotor position S.R. controllers are used for this purpose.

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Figure 6. Switched Reluctance Motor

2.4.1 Specifications KW range: up to 7.5 kW Speed range: (0-1500), (0-3000), (0-18000) rpm Efficiency: 80 to 90%

2.4.2 Features Very high speed range High starting torque Can operate at very high speed of the order of 8000-18000 rpm Powerful generator and powerful braking action Both AC and DC MOSFET based controllers Extra robust Minimum maintenance

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4. PRODUCTS FROM ECC(I)Ltd.

4.1.

Helicopter Traversing System

Drives and Controls for Helicopter Traversing System used in Naval Warships

were successfully developed by Eddy Current Controls (India) limited in 1994. This consists of a Drive cum Brake unit with an Electronic Control Module along with Control Panel, Control Desk, Junction Box, Cable Reel and Portable Control Box. The Drive is intended to Pull In and Pull out the Helicopter Securing and Traversing (HSAT) System. This becomes extremely difficult when the ship is mid sea because the ship may sway due to wave and wind forces which are highly unpredictable. The drive and brake should act in tandem according to the positive and negative loads acting on the HSAT System. Their Drives and Control System met all stringent quality standards set by Indian Navy and is presently installed on six Naval Warships.

3.2 . Electrically Operated Platform Truck

Eddy Electric Platform Truck is an off shoot of the Battery operated Vehicle research and development programme of Eddy Current Controls (I) Limited. The truck is designed to suit the efficient material handling in modern industries and godowns. Sophisticated DC Chopper Control Incorporated with the truck enables smooth and silent operation. The inbuilt protection scheme ensures a long life and an excellent performance. Productivity depends very much on the efficiency of Material Handling System or the movements of goods to be more specific. To ensure a smooth flow of goods in your production unit, electrically operated platform trucks have been introduced.

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Figure 7. Platform truck

Chassis: A robust fabrication made out of channels and plates. Drive Motors: A variable speed totally enclosed DC series motor. The motor is mounted above the drive wheel. Transmission: The Motor drive to the wheel is transmitted through a double reduction gear by a chain reduction. The drive motor and transmission system swivels on heavy duty self aligning bearings. Electrical System: For smooth acceleration and deceleration a MOSFET chopper control is provided for speed control. Forward/reverse motion Horn Light emergency cutoff Key switch

Brake two internal expanding shoes mounted on rear axle Extra option hydraulic lift, low voltage battery discharge alarm, lengthy platform

3.2.1. Special features

MOSFET Chopper Control. High Power Traction Motor.

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Fast and Smooth Acceleration. Low Voltage Protection of Battery

3.3.

Eddy mobility electric wheel chair

Drive motor: 250 W, 24 V Battery: Lead acid rating 24V, AH 10 Maximum speed: 2 to 4 kmph on flat ground Speed controller: speed variation by MOSFET chopper controller Feature of controller: smooth start, under voltage protection Joystick control Transmission: motor drive to the wheel is transmitted through a reduction gear box and a chain sprocket assembly resulting in smooth operation.

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4. APPLICATIONS

Sugar Industry Cane carrier - Main & Auxiliary, Diffuser, Striker, boiler feeder, Spreader, ID & FD fan drives Paper Industry Main drive of paper machine, brown stock washer, helper drive, slitter, ewinder, cutter, bleach washer, digester drum, roaster drum, pumpdrive.

Cement Industry Helper drive of rotary kiln-clinker & weigh feeder, table feeder, cooling fan drives, cement pipes-spinning, winding. Cable and allied industry Wire drawing, tubing, winding, capstan drive, copper casting. Conveyors & Feeders Coal feeder, Apron feeder, paddle feeder, airlock feeder, gravimetric feeder, volumetric feeder, screw feeder, table feeder, cranes, wagon tippler all types of conveyors.

Plastic & Chemicals Extruder main take up drive, granulator, agitator, centrifuge, mixer, liquid oxygen pump, chemical pump. Filetriever can accommodate entire filing system as per required design and can combine with different systems. This will create a systematic and automatic filing setup. It can deliver file with an average time of 30seconds.

Eddy Traction Series batteries with poly propylene containers are capable of withstanding the severe vibration occurring in vehicles. Eddy automobile series batteries are encased in strong hard rubber containers with a versatile multi-led-design.

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5. CONCLUSION
The ten day training at Eddy Current Controls (India) Ltd. had been informative and worthy. We familiarized with various kinds of drives, the technology behind them and their importance in commercial and scientific fields. We were offered a great deal of knowledge regarding electrically operated machinery, their control and support, and their future potentials.

We got to know more about drives, namely, dynodrives, switched reluctance drives, MOSFET based drives, AC and DC drives and Variable Frequency Drives. We developed an idea regarding tachogenerator, electrically driven platform truck, prototype of electric wheel chair and cycle, helicopter traversing system control unit and macroven (mega oven used as dryer). Besides this, we were introduced to an office automation project, Filetriever, being developed by the research and development wing of the company.

On the whole, this had been a new experience for our team. We were exposed to a newer way of learning, which was informative and exciting at the same time.

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6. REFERENCES

1. http://eddyindia.com/ 2. http://www.yaskawa.co.jp/en/# 3. http://www.srdrives.com/technology.shtml 4. http://sathisblog.blogspot.com/2007/06/replacement-of-dyno-drives-with.html 5. http://homepages.which.net/~paul.hills/SpeedControl/SpeedControllersBody.h tml

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