FUJI ELECTRIC JOURNAL September/2005 (Vol.78-No.5)

TOP PAGE System Control Components

Present View and Outlook for System Control Components
Mitsunori Fukuzumi, Kouetsu Fujita
System control components such as general-purpose inverters, servo systems, general-purpose programmable controllers (PLCs) and programmable operation displays (PODs) are required to provide higher performance and improved functionality at lower cost. In addition, their expandability and flexibility are also important factors when configuring a system. Recently, reliability and safety have also become important items to be evaluated when selecting components to configure a system. This paper presents an overview of the latest technical trends of the system control components introduced in this special issue, and also introduces Fuji Electric's various products series.

New SPH2000 CPU to Unite Sequence Control and Data Processing
Hideyuki Odaka, Takayuki Shimokawa, Yugo Sunaga
Together with the integrated MICREX-SX controller series, innovative modules are provided for constructing optimal control systems. Recent programmable controller (PLC) applications are expanded into new areas such as production status monitoring, traceability, and energy-savings supervisory control, in addition to control system automation. However, these applications require the processing of large quantities of data, a task for which PLCs are not well suited, and therefore a personal computer is commonly used in parallel with a PLC in these applications. This paper introduces the new SPH2000 CPU, which realizes dramatically improved performance in both the main PLC application of sequence control and in data processing functions, for which PLC performance had previously been inadequate.

New Features of PLC Programming Tools for the MICREX-SX Series
Noriyuki Nakama, Koji Fukushima, Daisuke Wakai
With the increasingly higher performance and functionality of machinery and systems, controller application software has become larger in size and more complex year after year. Controller support tools are requested to contribute toward the establishment of a more efficient development environment. Control support tools for the MICREX-SX integrated controller provide a highly efficient development environment throughout the entire lifecycle, from development to start-up, operation and maintenance, and support various development techniques ranging from conventional ladder diagram languages to full-fledged structured development method. This paper introduces the new features of PLC programming tools for the MICREX-SX Series.

Possibility of XML-based Distribution of PLC Software
Masayoshi Matsumoto, Koji Fukushima
As applications for programmable controllers (PLCs) become more diverse, control software is becoming more complex and larger in scope. In order to limit the steadily increasing software lifecycle cost, and to successfully increase productivity and quality to adapt to environmental changes, a multi-vendor environment in which products from different vendors can be integrated easily is desired. This paper describes Fuji Electric's efforts targeting software that complies with IEC61131-3, which is being promoted jointly with PLCopen Japan, to use XML to enable the shared use of software among different machines, and also explores the feasibility of new software distribution channels.

Expanded Line of MICREX-SX Components
Yutaka Yatsuda, Yutaka Saitoh, Koichi Ohara
In recent years, the range of applications for programmable controllers (PLCs) has continued to expand and develop, becoming more diverse with the adoption of open standards and multifunctionality, and consequently, there is no shortage of marketplace requests for PLCs. Since the MICREX-SX integrated controller was first released, it has precisely satisfied market needs as a global system component. Focusing on the latest product group, this paper describes the expanded line of MICREX-SX components and also discusses their certification.

MICREX-SX Makes the System Run Safely
Yasutaka Fujikawa, Hideto Tokuma
The MICREX-SX integrated controller is able to implement redundancy for each element, including the networks necessary to realize safe continuous system operation. This paper presents an example of a system that makes full use of this redundancy function. This system performs surveillance and monitoring, and has the characteristic features of CPU redundancy, network module redundancy, loop topologybased network redundancy, module hot-swappable capability, batteryless operation, etc.

Application of MICREX-SX to the Fields of Air-conditioning and Energy Conservation
Fumio Ito
With the revision of the Japanese Law Concerning the Promotion of Measures to Cope with Global Warming, many plants and office buildings must implement energy management. Accordingly, to reduce energy consumption and greenhouse gas emissions, records of energy usage and the like and measures to conserve energy are needed. Remote monitoring is being considered for this purpose. In response to this need, a web-based monitoring system that enables remote monitoring from any location at any time has been configured from controllers that are equipped with web servers and installed at various locations. This type of web monitoring system has been applied to the field of air-conditioning and is introduced in this paper.

Example of Flexible System Configuration with a MICREX-SX and an AS-i Network
Jun Ito, Yasutaka Fujikawa
The MICREX-SX integrated controller has been successfully applied to many systems, but a plan for total cost reduction is especially important when considering the installation of such a system. The reduction of development costs by creating software more efficiently and the lowering of installation costs by reducing wiring use are large challenges. This paper introduces a parts rack picking system and a building facility automated control system as examples of flexible system constructed using a MICREX-SX and a wire-saving system as an AS-i network.

Application of the MICREX-SX to a Steel-process Line
Yasunobu Tsutsumi, Sadahiro Sugimoto, Yoshimi Sato
This paper describes the application of the MICREX-SX integrated controller and D300win programming tool to a continuous annealing line (CAL) used in a steel plant. Features of the programmable controller (PLC) programming language standard IEC 61131-3, i.e., "control functions that are reusable as user function blocks (FBs)," "programming according to address specification and labels," "selection of programming language according to control details," and "data structuring according to control objects," are fully utilized to realize efficient software design.

FRENIC-Multi Series of General-purpose Compactsize Inverters
Osamu Shiokawa, Norio Hirai, Toshiya Ito
As general-purpose inverters are applied to an ever-wider range of applications, higher performance and functionality than in the past is being required. To develop such inverters for a globally diversifying range of applications, attributes such as ease-of use, excellent maintainability, smooth interaction with peripheral devices, and the like are necessary. Developed in response to these market requests, the FRENIC-Multi series is anticipated to be widely accepted in the market place due to its environmentally-friendly design, support of RoHS directive, and because it prolongs the service life of finite-life components. This paper presents an overview of the FRENIC-Multi Series.

FRENIC-Eco Series of Inverters for Fan and Pump Applications
Takashi Nakanishi, Yasushi Kondo, Osamu Mizuno
With the heightened awareness of global environmental conservation, there is increased demand for energy savings in order to reduce CO2 emissions. Fan and pump inverter applications such as HVAC (heating, ventilating and air conditioning system) that exhibit a large energy savings effect due to the use of an inverter are trending toward increased inverter use, and the market severely needs the requested functionality and performance. The FRENIC-Eco Series is specially designed for fan and pump applications, and was developed to provide fans and pumps with optimal functions and performance. This paper describes the characteristic features of the FRENIC-Eco Series.

FRENIC-Lift Series Designed for Elevating Machinery
Tetsuya Nomura, Hiroaki Kato, Masahiro Sato
In the elevator market, standard elevators are transitioning from geared elevators to gearless elevators. Accordingly, inverters for elevators are required to be powerful and to provide high performance. The newly developed FRENIC-Lift Series realizes high performance operation by means of full vector control with a high-speed current control system, and a high overload rating (200 % for 10 s) made possible by special design for the elevator that uses new generation IGBT. This paper presents an overview of the FRENIC-Lift Series and provides examples of its characteristic features.

Large-capacity Inverters
Masato Mochizuki, Masahiro Aoyama, Tatsuya Yamada
With the widespread use of inverters in motor driving applications, demand has increased for inverters capable of driving large motors. In response, Fuji Electric has developed an inverter unit capable of driving a 710kW (max.) motor with a single inverter and an inverter stack capable of driving an 800kW motor. This paper introduces the circuit configuration and technology of Fuji Electric's large capacity inverters, and also describes a multiplex system that uses several inverters.

Applications for General-purpose Inverters
Yuji Fukushima, Tsutomu Ohyama, Masahiro Minami
Year after year, demands on the general-purpose inverters used in various industrial fields have increased toward higher performance, higher functionality and better system support. This paper presents examples of inverter applications to a wire drawing machine, a spooler and a strand machine, application to an inverter/commercial switch, and application to a bearing heater.

Induction Heating Inverter 3kW/5kW
Takanobu Kadogaki, Masaru Nakai, Michio Tamate
Commercial induction heating (IH) inverters are used primarily in commercial kitchen appliances, as well as other general industrial heating applications, as a source of induction heating. Because an IH inverter directly heats the object to be heated, it has excellent thermal efficiency and is effective in preventing an increase in CO2 which is a cause of global warming. This paper presents an overview of Fuji Electric's recently developed core product for commercial kitchen appliances, the new model 3kW/5kW IH inverter known as the HFR-C11K.

New FALDIC-W Series of Servo Systems
Akihiro Ito, Kayo Tsuzaki, Atsushi Narita
Fuji Electric's FALDIC-W Series has been developed based on the concept of providing "servo systems for evolving machinery." With the higher level of performance achieved by Fuji Electric's proprietary vibration control, and a motor that supports 3 series of rated rotating speeds, and an IP67 protection rating, this series is suitable for various applications. Ease of use is dramatically improved with an image tuning function that automatically sets the optimal tuning gain and the provision of two RS-485 ports that enable the centralized control of parameters with an upper level controller.

Application to Multiaxial Synchronous Servo Systems
Tadakatsu Aida, Masami Marubayashi
Motion control systems used in such applications as printing machinery, machine tools and food processing equipment are required not only to have easier handling and lower cost, but also to be capable of supporting large-scale multiaxial systems. This paper describes a method for implementing synchronous control by using the MICREX-SX integrated controller and the FALDIC- servo system, without the need for a costly dedicated module for motion control, and presents examples and describes the features of applications ranging in size from a 4-axis small-scale system to a 32-axis multiaxial system.

Application to a Vector Inverter Synchronous System
Takashi Ida, Tadakatsu Aida, Masahiro Kina
In recent years, similar to servo systems, demand has increased for synchronous position control and multiaxial control in line control applications such as steel plate, paper and film cutting, while at the same time, lower cost is also being required. This paper describes a method for using the general-purpose MICXREX-SX integrated controller and FRENIC5000VG7S high-performance inverter to implement synchronous positioning control without the need for a dedicator controller, and also presents an example of application of a synchronous positioning system to a rotary shearing machine.

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