PLC Automation of Drive Power Cycling: A Test System Improvement
Satta, Jukka (2025)
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:amk-202501071069
https://urn.fi/URN:NBN:fi:amk-202501071069
Tiivistelmä
ABB Oy Drives has a test system called mixed flowing gas tester, with the purpose of studying the effects of corrosion on drives. During the tests, the drives are cycled on and off with an automated power cycling system. There have been several shortcomings in the test system, including necessary cable replacement in a difficult narrow space, very limited software, unorganized hardware and poor documentation. The purpose of this thesis project was to reduce and eliminate these shortcomings by creating a new automated power cycling system controlled by a programmable logic controller and clearly documenting its hardware and software.
The new power cycling system was created and installed according to its requirements. The new design succeeded in making cable replacement considerably more convenient, and the new hardware layout was clear and well-documented. The new software works according to specifications but could be developed with more flexibility and features. A capacitor discharge issue in the system was overlooked, which resulted in large transient currents breaking a contactor. The issue was fixed by limiting the software. Overall, the system was a success and is fully functional. Development of new features for the system continues after this thesis report.
The new power cycling system was created and installed according to its requirements. The new design succeeded in making cable replacement considerably more convenient, and the new hardware layout was clear and well-documented. The new software works according to specifications but could be developed with more flexibility and features. A capacitor discharge issue in the system was overlooked, which resulted in large transient currents breaking a contactor. The issue was fixed by limiting the software. Overall, the system was a success and is fully functional. Development of new features for the system continues after this thesis report.