Abstract
This paper proposes the novel idea of eliminating the front-end converters used indirect current (DC) bus voltage variation, thereby allowing for control of the speed of the brushless direct current (BLDC) motors in the two-quadrant operation of a permanent magnet brushless direct current (PMBLDC) motor, which is required for multiple bi-directional hot roughing steel rolling mills. The first phase of steel rolling, the manufacture of plates, strips etc., using hot slabs from the continuous casting stage, is carried out for thickness reduction, before the same is sent to the finishing mill for further mechanical processing. The hot roughing process involves applying high, compressive pressure, using a hydraulically operated mechanism, through a pair of backup rolls and work rolls for rolling. Overall, the processes consist of multiple passes of forward and reverse rolling at increasing roll speeds. The rolling process was modeled, taking into account parameters like roller dimensions, angle and length of contact, and rolling force, at various temperatures, using actual data obtained from a steel mill. From this data, speed and torque profiles at the motor shaft, covering the entire rolling process, were created. A profile-based feedback controller is proposed for setting the six-pulse inverter frequency and parameters of the pulse width modulated (PWM) waveform for current control, based on Hall sensor position, and the same is implemented for closed loop operation of the brushless direct current motor drive system. The performance enhancement of the two different controllers was also evaluated, during the rolling of 1005 hot rolled (HR) steel, and was taken into consideration in the research analysis. The entire process was simulated in the MATLAB/Simulink platform, and the results verify the suitability of an entire-drive system for industrial steel rolling applications.
Highlights
Steel manufacturing is a highly power-intensive process, wherein about 8% of the total energy consumption is absorbed in hot steel rolling
It consisted of an IGBT-based intelligent power module (IPM), the brushless direct current (BLDC) motor belt coupled to a direct current (DC) generator, and the load arrangements
A total system for hot rough steel rolling, consisting of a BLDC motor drive, coupled to a set of work rolls and backup rolls, along with a closed loop controller, with a multi-loop configuration has work rolls and backup rolls, along with a closed loop controller, with a multi-loop configuration has been presented in this paper
Summary
Steel manufacturing is a highly power-intensive process, wherein about 8% of the total energy consumption is absorbed in hot steel rolling. Electronics 2020, 9, 1149 like the dimensions of the roller, the work temperature, and the metallurgical properties, are considered during the rolling process, while the torque and rolling force need to be calculated during the multi-pass. The work temperature, and theforward–reverse metallurgical properties, considered calculations facilitatewhile fixingthe thetorque speed of therolling shaft and the torque that constituteduring the operating points the rolling process, and force need to be calculated the multi-pass of the motorProfiles that is driving. The involving the back force), suchfor as ten the passes currentofofsteel the stator, The characteristics performance characteristics of theEMF drive(electromotive motor were ascertained rolling. The speed of the shaft, and the electromagnetic torque are clearly manifested in this paper by means of simulation
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