PHD THESIS SUMMARY

IMPROVMENT OF ELECTRICAL DRIVES OF SOME MAIN SHAREHOLDERS

OPERATION IN OPEN PIT JILT FOR INCREASING ENERGY EFFICIENCY

Scientific :
University professor PhD eng.MIHAI PSCULESCU

PhD student:
eng. MARCIAN ANDRU
KEYWORDS:
Bucket-wheel excavators, bucket wheel, spreader, high capacity conveyor belt, the main
shareholders, electric drives, frequency converter, asyncronous induction motor,
modernzation, rehabilitatio, experimental testing, critical analysis, comparative study,
excavation parameters, power drive, capacity excavation, high bars squirell-cage motor, high
impedance bars motor, energy efficiency, effort concentrators, torsion torque, 3D images
magnetic circuit, the harmonics content
CONTENT
PREFACE ...................................................................................................................................... 4
INTRODUCTION......................................................................................................................... 5
GENERAL DATA.. 11
CHAPTER 1
PRESENTATION OF TECHNOLOGICAL FLOW AND RELATED SHAREHOLDERS
WHICH BELONG TO OPEN PIT JILT.TECHNOLOGICAL EQUIPMENT .................. 13
CHAPTER 2
ACHIEVEMENTS AND TRENDS IN FREQUENCY CONVERTER-ASYNCRONOUS
MOTOR DRIVES ...................................................................................................................... 30
2.1. Introduction30
2.2 Actual general trends.
31
2.2.1 Reliability increase...................................................................................................... 31
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2.2.2 Operator interface improvment................................................................................. 31

2.2.3 Increased robustness................................................................................................... 32
2.2.4 Auxilliary functions improvment............................................................................... 32
2.2.5 Reducing the cost ........................................................................................................ 33
2.3. Technical trends
33
2.3.1 Electronic power devices ............................................................................................ 33
2.3.2 Power electronic converters ....................................................................................... 37
2.3.3 AC electrical drives control........................................................................................ 38
2.4. Implementation of static frequency converters for control squirrel cage asynchronous
motors ......................................................................................................................................42
2.4.1.Abstract........................................................................................................................ 42
2.5. Additional losses in asyncronous motor due harmonics content od supply
voltage
43
2.5.1 Abstract........................................................................................................................ 43
2.5.2 Additional losses in asyncronous motor windings ................................................... 43
2.5.3 Ferromagnetic core losses in the motor .................................................................... 46
2.6. CRITICAL ANALYSIS OF ROMANIAN(SNLO) OPEN PIT MODERN
SHAREHOLDERS ELECTRICAL DRIVES
46
2.7. Conclusions.55
CHAPTER 3
MODERNIZATION OF TECHNOLOGICAL FLOW SHAREHOLDERS DRIVES FROM
ROMANIAN OPEN PITS .......................................................................................................... 57
3.1 Considerations on electrical drives modernization of open pit mining equipment 57
3.1.1. Bucket-wheel drive..................................................................................................... 58
3.1.2. Bucket-wheel(dump) conveyor belt slewing drive .................................................. 59
3.1.3.Moving mechanism drive ........................................................................................... 60
3.1.4.High capacity conveyor belts ..................................................................................... 60
3.3. CONCLUSIONS. 62
CHAPTER 4
REHABILITATION AND MODERNIZATION OF TECHNOLOGICAL FLOW FROM
LIGNITE OPEN PIT CONSIDERATING RELIABILITY GROWTH AND ENERGY
SAVING ...................................................................................................................................... 64
4.1 Abstract.
64
4.2. Restructuration objectives in one lignite open pit.. 65
4.2.1. Mechanical drives rehabilitation .............................................................................. 65
4.2.2. Electrical drives rehabilitation ................................................................................. 67
4.3. Modernization and increase reliability of some Jilt open pit shareholders 69
4.4 Identification of electrical modernization solutions ...70
4.4.1 ERC 1400 i ERC 1300 bucket-wheel excavator modernization............................ 70
4.4.2 MH spreaders modernization .................................................................................... 71
4.4.3. Conveyor belts drives moderization......................................................................... 71
4.4.4 Electrical modernization-technical advantages ....................................................... 83
CHAPTER 5
AUTHORS CONTRIBUTIONS IN LIGNITE OPEN PIT TECHNOLOGICAL FLOW
EQUIPMENT REFURBISHMENT .......................................................................................... 84
5.1.ERC 1400 Bucket-wheel drive optimization using high-bars squirell-cage motor..84
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5.1.1Bucket-wheel motor calculation 85

5.1.2 Motor drive characteristics ...................................................................................... 101
5.1.3 Ferromagnetic 3D images and windings................................................................. 109
5.2 Conveyor belt drives optimization trough high impedance bars motor.. 111
5.3.Energy efficiency calculation for high impedance bars motor(squirell-cage
rotor). 115
5.3.1 Technological flow energy efficiency analysis ....................................................... 115
5.3.2. Solution effectiveness comments............................................................................. 119
5.4. Electromagnetic calculation breviary 630 kW/82rpm motor.
121
5.4.2.Mechanical calculation breviary 630kW/82rpm motor ........................................ 127
5.4.3.The arrow shaft during operation at rated speed ................................................. 133
5.4.4 Shaft maximum efforts ............................................................................................. 134
5.4.5 Concentratorii de efort pe elementele componente ale Ans. Arbore ................... 134
5.4.6. Shat effort concentrators......................................................................................... 135
5.4.8 Pure torsion torque is given by motor rated torque .............................................. 136
5.4.9. Imposed conditions .................................................................................................. 140
5.4.10 Comparative measurements to drive motor 83 rpm and wound rotor motor
drive and gear box ............................................................................................................ 142
CHAPTER 6 .............................................................................................................................. 144
FINAL CONCLUSIONS .......................................................................................................... 144
BIBLIOGRAPHY ..................................................................................................................... 146
APPENDIX ................................................................................................................................ 153
CURRICULUM VITAE

PHD THESIS SUMMARY

IMPROVMENT OF ELECTRICAL DRIVES OF SOME MAIN
SHAREHOLDERS OPERATION IN OPEN PIT JILT FOR INCREASING
ENERGY EFFICIENCY
Scientific :
University professor PhD eng.MIHAI PSCULESCU
PhD student:
eng. MARCIAN ANDRU
Ellaboration of this thesis was based on my profesional experience and my research
activity regarding main mining equipments which compose the technological flow of Mining
open pit Jilt.Research activity made on medium voltage equipments which ocure the Mining
open pit Jilt coal exploitation technological flow was developed together with an complex
research team composed mainly by Mr Nicolae Bercea,Mr Alexandru Dragoescu and Mr Ion
Cioc and many other specialists.
The main goal of my research was identification of improvment for electrical drives
control system which represent the interface between Mining open pit Jilt technological flow
and energy efficiency materialized in the concluding outline feedback energy balance
Based on these considerations we investigated the possibility of using an electric motor with
high bars, research that has resulted in a national patent and even with a consistent
implementation of these types of electric motors in technological flow scheme.
Also developed in this study we present a modern solution of using medium voltage
asynchronous electric motors with squirrel cage, special designed to train coal conveyor belt,
drive the classical solution aimed not geared,for start and long-term operation correlated with the
flow of excavated material by means of static frequency converters. .
In Chapter I presents the Careers stall mining, presentation of which stand out the
exploitation of surface specific technical and economic indicators that characterizes. The mining
exploitation is one of the largest in South-Eastern Europe with only:

14 Bucket-wheel excavator type ERC 1400.30/7

8 spreaders type MH 6500x90,MH 4400x170;

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2 combinated shareholders operation KSs 5600x60;

1 spreader type ASG 6000x40;
93 high capacity conveyor belts .
In Chapter II is an overview of achievements and trends worldwide in the electrical
drives, mathematical models of electrical machines driven by frequency converter and critical
analysis of minieritul shareholders in Romania.
In recent years, drives with static converter - induction motor has become a preferred
alternative in type adjustable drives .Multivariable, adaptive technology , optimal, including
estimates of state and parameter identification in real time as well as field oriented control its
variants that allowed shareholders to reach and even exceed, the dynamic performance of DC
drives All these were possible only with the progress in large-scale integrated circuits for general
use ASIC (Application Specific Integrated Circuit), the microprocessors 16 and 32 bits of 16-bit
microcontrollers and more recently, the processor signal DSP (Digital Signal Proccesor) that
enable implementation of complex algorithms in real time.
The analysis of career interruptions accidental equipment 18.5% are distributed within the
technological power interruptions as follows:
54.8% of power outages are located in high capacity conveyors;
34.7% one of the power outages are located in bucket-wheel excavators
10.5% of power outages are located in spreaders.
Chapter III contains a review of electrical drives upgrades in equipment technology
flows in the surface mining Romania.prezentandu the measures taken and critical analysis of the
results of implementing these upgrades
.
Were upgraded with predilection drive belt conveyors, drive mechanism driving the ERC
rotor excavators and dump those for cars MH mecanismult drive rotor pivot arm band that the
deposit port wheel drive cups RPC mechanism.
The advantages of these upgrades are highlighted in critical analysis of the results of
implementing measures to modernize
Chapter IV deals with the rehabilitation and modernization of technology lines from a
lignite quarry in order to increase reliability and reduce consumption energie.Is presented
concrete measures taken in this direction for each type of equipment mainly lignite quarries
For all these measures successfully implemented in the most spectacular lignite
quarries belong to the author, namely
Mounting cage motors with high bar under patent EN 121359B1 large capacity
conveyors belts.Is presents broad technical details related to this action and their
advantages and disadvantages arising from the execution aceasta.One version of this type
of motor was also implemented the port wheel drive bucket rotor excavators
Installation of frequency converters and change actuator conveyor belts high capacity
to eliminate the mechanical gearbox turatie.Se detail the operation and benefits of this
measure

Chapter V is reviewing the main contributions of the author in the direction of

increasing energy efficiency that
1. Having the privilege to work with the famous professor, Mr. Ion Cioc I patented an
electric motor with high bars to optimize shareholders port wheel mechanism on the excavator
bucket rotor motor ERC 1400 by implementing special dedicated high bar mechanism instead
of conventional shareholders rheostat dry motor run under patent and calculated according to
calculation presented in the thesis
2. Using the special form described in the patent bar participated in design then tested
and successfully implemented the scheme of technological process of career stall to over 80
special shareholders average engine speed low-voltage-750rpm respectively coupled directly
to the power supply network to start
3. Algorithm developed for calculating the energy efficiency engine high bar
implemented within the technological
4. Managed execution and commissioning of medium voltage motor and a very low
speed direct drive conveyor belts dedicated to eliminating chain-speed gearbox shareholders
Chapter VI contains the conclusions of the author on effective solutions obtained
following the implementation of their careers and contributions of lignite
The widespread use of the solutions proposed by the author to make substantial savings
in operating costs, savings which can become important sources of investment to optimize
production (author considers that the proposed solutions generalize the entire surface mining
in Romania would generate annually over 100 million euros). This latter conclusion is
substantiated by the following evidence:
Reduce specific energy consumption substantially and eliminated electroassemblyload of equipment
It minimizes maintenance, overhaul and repair
Increase reliability by replacing dynamic electrical switchgear with static
commutation
The Appendix presents:
computation of a low speed motor and frequency converter features for electrical drives
modernization of mining conveyors, mechanical gearbox eliminates the carrier component
shareholders
Measurements of electrical main contributions of the author
Patents and patent applications of the author to confirm the applicability and novelty of the
author's own contributions
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CURRICULUM VITAE

1. Name: Sandru
2. Surname: Marcian
3. Birth date and place: 19.07.1963 Targu-Jiu city, Gorj county
4. Citizenship : Romanian
5. Education:
Institution:
Periode:
Institution:
Periode:
Degree or diplomas:
Institution:
Periode:
Degree or diplomas:

Primary Education
Tg-Jiu ,No. 4 Primary School
sept 1970 juni 1978
Tg-Jiu ,Tudor Vladimirescu National College
sept 1978 june 1982
Baccalaureate degree and certified electrician
UNIVERSITY
Bucharest Polytechnic Institute
sept. 1983 - iunie 1988
Electrical engineering degree

6. Expertise:
Periode
Place
Institution
Function
Periode
Place
Institution
Function
Periode
Place
Institution
Function

15.08. 1988 30.11. 1993

Targu-Jiu
IAMSAT Bucuresti
Site manager
01.10.1997 30.03.2004
Jilt
Oltenia Lignite National Company
Energy Chief Engineer
01.01.2005 01.11.2011
Targu-Jiu
SC MARSAT SA TG-JIU
Chief of Operating Officier

16.12.1993 01.10.1997
Jilt
IM Jilt-Sud
Chief Electrical Section
01.04.2004 01.01.2005
Jilt
Complexul Energetic Turceni
Energy Department Chief
01.11.2011 - prezent
Targu-Jiu
SC DASCONSULT SRL
Administrator

8. Published documents: 10 documents (author or coauthor);

9. Membership in professional associations: ANEVAR;
10. Foreign languages: English, French;
11. Technical skills and competences: ANRE Authorization IIIA / IVB
ANEVAR Expert
computer using;

Petroani, 30.06.2012

eng. Sandru Marcian

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