Referentie 31 januari 2022

Gegarandeerd veilige energievoorziening

Bij de spanningsvoorziening van productiesystemen speelt veiligheid een belangrijke rol. In laagspanningsverdelingen worden meestal vermogensschakelaars gebruikt om overstromen veilig te vermijden en de spanningsvoorziening in geval van een kortsluiting uit te schakelen. De bewaking van de systemen is daarom van cruciaal belang om de energievoorziening bij een storing snel te kunnen herstellen. Schaeffler, toeleverancier voor industrie en automobielindustrie, maakt voor de productie van rollagers in het Duitse Schweinfurt gebruik van de veldbuscouplers van WAGO.

Bij de productie van rollagers worden diverse machines voor koudvervormen, smeden, verspanen, thermische behandeling en coatingtechniek toegepast. Op de locatie Schweinfurt in de Zuid-Duitse deelstaat Beieren verwerkt het bedrijf jaarlijks ca. 80.000 ton staal voor de productie van rollagers en bijbehorende producten, en dat voor de meest uiteenlopende toepassingsgebieden – van automobielindustrie tot de productie van windturbines. Een goed functionerende energievoorziening van de installaties en de systemen is voor Schaeffler het belangrijkste onderdeel van de infrastructuur.

Veilig – met veldbuscouplers van WAGO:

Energievoorziening van machines
Bewaking van de vermogensschakelaars op afstand
Alarmering - gedetailleerd en 24/7
Eenvoudig te modificeren en uit te breiden

Energievoorziening van machines

Op het fabrieksterrein in het Zuid-Duitse Schweinfurt zijn dan ook meerdere voedingen van het middenspanningsnet aanwezig. Deze voeden de transformatorstations met ruim 100 transformatoren, die wederom ruim 30 laagspanningsverdelingen van energie voorzien voor de voeding van alle machines in de productie. "De veiligheid en de betrouwbaarheid van de energievoorziening zijn voor ons enorm belangrijk", aldus Julian Kübler, verantwoordelijk voor de bewaking van de midden- en laagspanningsschakelsystemen in de Schaeffler-fabriek in Schweinfurt. In de systemen zelf zorgen vermogensschakelaars voor de afzonderlijke beveiliging van de uitgangen voor de elektrische verbruikers. Hierbij is iedere vermogensschakelaar in een eigen veld in de schakelkast ondergebracht. Bij verbruikers met een geringer vermogen zijn gedeeltelijk ook meerdere kleine vermogensschakelaars in een veld gemonteerd. Een normale installatie bestaat uit ongeveer twee tot drie bereiken met elk 15 tot 20 velden en een totaal vermogen van elk ca. 2.000 kVA.

Bewaking van de vermogensschakelaars op afstand

Bij de bouw van de laagspanningssystemen in 2015 werd een alarmsysteem voor storingen ingepland. "Tot dusverre konden de installaties en de systemen alleen een collectieve storing activeren, die vervolgens aan het veiligheidsbeheersysteem werd overgedragen", licht Kübler de nadelen van het oude systeem toe. Hierbij werd een ringleiding voor de overdracht van de alarmen van alle vermogensschakelaars gebruikt. Op afstand kon hierdoor echter niet worden vastgesteld welke uitgang onderhevig was aan de storing. Om dit nauwkeurig vast te kunnen stellen, werden in eerste instantie de melduitgangen van alle vermogensschakelaars naar een extra schakelkast in de buurt van de installatie geleid. Hier zorgde een controller voor de verwerking van de signalen en gaf de desbetreffende meldingen door aan het beheersysteem. "Het bedraden kostte bij deze oplossing echter ontzettend veel tijd en moeite", vertelt Kübler. Daarom zijn we op zoek gegaan naar een alternatieve oplossing."

De medewerkers van Schaeffler vonden de perfecte oplossing bij WAGO. Met de veldbuscouplers en de busklemmen van het modulaire WAGO I/O-SYSTEM 750 is hardware beschikbaar waarmee de verwerking van storingsmeldingen aanzienlijk eleganter gerealiseerd kan worden. Hiervoor werd ieder schakelkastveld van het systeem uitgerust met een PROFINET-coupler. Deze bevat een digitale ingangsklem met 16 kanalen en beschikt zodoende over voldoende capaciteit om alle meldingen van de vermogensschakelaars gedetailleerd te analyseren. Een centrale controller functioneert in PROFINET als master en leest de signalen van de PROFINET-couplers uit – de verdere verwerking en de aansluiting op het beheersysteem functioneren op de welbekende manier. Het gebruik van de PROFINET-couplers van WAGO heeft voor Kübler een belangrijk voordeel: "We kunnen de couplers gewoon met patchkabels van veld tot veld met elkaar verbinden. Aangezien we gebruik maken van een ringtopologie, functioneert het systeem ook als een patchkabel onderbroken is." De kabels worden direct via de interne kanalen in de schakelkasten met elkaar verbonden. Een tijdsintensieve bekabeling door de dubbele vloer onder de installatie is hierdoor overbodig. Aangezien zowel de besturingskabels als de krachtstroomkabels van de vermogensschakelaars naar de verbruikers door de gemeenschappelijke kabelaansluitruimte werden geleid, zouden de desbetreffende uitgangen voor het plaatsen van de signaalkabels spanningsloos geschakeld moeten worden.

Alarmering – gedetailleerd en 24/7

Het beheersysteem, waarmee de medewerkers de status van alle vermogensschakelaars kunnen bewaken, bevindt zich in de onderhoudswerkplaats. De status van de gehele energievoorziening wordt hier transparant gevisualiseerd. Het nieuwe storingsmeldingssysteem, dat nochtans in drie laagspanningssystemen is gemonteerd, voorziet in aanzienlijk meer functies dan de tot dusverre toegepaste oplossing. In geval van een storing herkennen de onderhoudsmedewerkers welke vermogensschakelaar werd geschakeld en welk defect waar aanwezig is. De veiligheidscentrale ontvangt eveneens gedetailleerde storingsmeldingen en kan de dienstdoende servicemedewerker belangrijke informatie geven voordat deze bij de installatie aankomt. "Op deze wijze kunnen we de veiligheid van onze laagspanningsvoorziening en dus ook de beschikbaarheid van onze productiesystemen verhogen", vertelt Kübler verheugd.

Eenvoudig te modificeren en uit te breiden

Naast de eenvoudige bekabeling zijn de compacte afmetingen van de PROFINET-couplers van WAGO een doorslaggevend voordeel. "We konden de couplers met minimale aanpassingen op de aanwezige DIN-rails in de afzonderlijke schakelkasten integreren", licht Kübler toe. Net zo eenvoudig konden de componenten van WAGO in het reeds aanwezige engineeringsysteem worden geïntegreerd. Het systeem kan flexibel uitgebreid worden. In de toekomst dienen de vermogensschakelaars bijvoorbeeld via de centrale controller geschakeld te worden. Deze wordt vanaf het beheersysteem of ter plaatse met de afstandsbediening aangestuurd. Hiervoor hoeven de PROFINET-couplers alleen van een digitale uitgangsklem voorzien te worden. "De schakeling op afstand heeft het voordeel dat de operator in geval van een kortsluiting of een mogelijke vlamboog niet direct vóór de schakelkast staat", aldus Kübler.

van Frank Sünkel | 12.10.2016

Foto's: Anand Anders/vor-ort-foto.de

Productoverzicht

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WAGO in de praktijk

Referenties uit het bereik productietechniek

Als partner en innovator realiseert WAGO tal van interessante projecten. Ervaar hier welke creatieve en efficiënte oplossingen wij op het gebied van productietechniek mogelijk maken.

Onderhoudsvrij en tijdbesparend

CNC-boormachines van Schmoll worden wereldwijd ingezet. Bij het bedraden van de elektrische installatie worden TOPJOB® S-rijgklemmen van WAGO gebruikt.

Passende automatisering voor modulaire machines

In de speciale machinebouw zijn modulaire oplossingen een absolute must voor de aansluiting van actuatoren en sensoren. WAGO speelt met een breed productportfolio perfect hierop in.

Pioniers projecteren in recordtijd

Bij Nordson worden de meest uiteenlopende machines in recordtijd ontwikkeld. Dit is mogelijk dankzij de automatiseringsmodules en de engineering software e!COCKPIT van WAGO.

Uw contactpersoon bij WAGO

Andere serviceaanbiedingen:

Aanbevolen artikelen

Meer uit het bereik oplossingen

Automatiserings- en contacttechniek van WAGO is niet alleen vertegenwoordigd in de productietechniek. Ervaar hier welke oplossingen WAGO in andere branches biedt.

Energietechniek

De digitale toekomst

De energiesector heeft op alle vlakken te maken met grote uitdagingen. Intelligente netwerken en innovatieve oplossingen van WAGO bieden hulp bij het aangaan van deze uitdagingen.