Prof. dr. ir. Johan CATRYSSE

Transcription

1 EMC: How to handle large machinery Prof. dr. ir. Johan CATRYSSE FMEC, KHBO, Oostende (BE) MICAS/ESAT, KULeuven (BE) 1

2 Overview 2 Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions

3 Introduction: the actual ambient 3

4 Overview 4 Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions

5 Large Machinery 5 Machinery Emergency stop electronics Input / output of materials Access by operator PDS PS Motor Mains

6 Large Machinery 6

7 Overview 7 Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions

8 EMC Directive 2004/108 and Harmonised Standards for machinery 8 Application of HS Apparatus Product type EMC assessment Optional report from notified body Technical Documentation D.o.C. Name of : manufacturer importer Installation Application of protection requirements Type : xxx-yyy S/N :

9 EMC Directive 2004/108 and Harmonised Standards for machinery 9

10 EMC Directive 2004/108 and Harmonised Standards for machinery 10 EN Electromagnetic Compatibility (EMC) Product family standard for machine tools Part 1: Emission EN Electromagnetic Compatibility (EMC) Product family standard for machine2 tools Part 2: Immunity If a specific product standard exists, it overrules the use of EN X Examples: PDS: EN PLC: EN Power Supply: EN IT EN (CISPR 22) Note: All of them refer to the basic standards for test setups (e.g. CISPR)

11 EMC Directive 2004/108 and Harmonised Standards for machinery 11 CHOICE OF PROCEDURE Procedure A Procedure B Procedure C Prepare Machine Prepare entire electrical set Divide into EM relevant modules Type Test Type Test Type Test Visual inspection Visual inspection Additional test on machine END

12 Overview 12 Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions

13 TEMCA2 project 13 TEMCA2, Alternative EMC testing methods for large machines, No. G6RD-CT for the 5th European Framework Program, GROWTH, Objective (Methodologies to support standardisation) The three main objectives of TEMCA2 were: development of new methodologies and methods for the evaluation of conducted and radiated emission, generated by large machinery, as an alternative to the existing harmonized standards development of new methodologies and methods for the evaluation of immunity of large machinery, as an alternative to the existing harmonized standards expertise transfer by means of a guideline for machine manufacturers

14 Overview 14 Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions

15 15 Conducted Emission The main problem for large machinery is related to two items: the current consumption, and the current handling capacity of a LISN the fact that it is nearly impossible to insert a measuring probe in the power mains cabling If possible, to develop measuring setups, with a non-contacting probe for the power mains Therefore, a number of possible alternative methodologies have been analysed, and an example of measuring results is given in the next sections

16 Conducted Emission 16 LISN used as a voltage probe (or LISN in parallel )

17 Conducted Emission 17 CISPR 11 voltage probe 1500/50 Ohm

18 Conducted Emission 18 Capacitive Voltage Probe (CVP)

19 Conducted Emission 19 EFT Capacitive clamp used as capacitive voltage probe

20 Conducted Emission 20 Capacitive Foil Probe (CFP) Foil Crocodile clamp Cable duct (GRP) Measurement wire GRP connection

21 Conducted Emission 21 Capacitive Foil Probe (CFP) - calibration setup 0 KHBO CALIBRATION CAPACITIVE FOIL PROBE (CFP) (Injected signal: 0 dbm) -10 Received signal (dbm) db/dec -38 dbm -18 dbm dbm -70 0, Frequency (MHz)

22 Conducted Emission 22 Capacitive Foil Probe (CFP) - CRYPTE (ONERA) analysis & simulation 1 mm 30 cm mm mm mm 4 Z 1 =50Ohm (receiver)

23 Conducted Emission 23 Capacitive Foil Probe (CFP) - CRYPTE (ONERA) analysis & simulation L8 16uh R1 6 L11 2.5uh R18 2 L9 16uh R2 6 T34 in1 out1 in2 out2 in3 out3 T3coupledX C1 2uf L1 250uH C2 R9 5 L2 50uH 8uf 1uf L6 1.7mh 2uf C4 C3 C7 1uf R11 L3 250uH 50 L4 50uH C5 8uf R10 L5 5 C6 1uf C8 1uf 1.7mh R12 50 T19 in1 out1 in2 out2 in3 out3 T3coupledX C9 2.2uf L10 2mH K K1 K_Linear COUPLING = mH L20 R C10 2.2uf C12 4.7nf L30 2mH K K2 K_Linear COUPLING = 0.99 L40 2mH C11 4.7nf V4 R6 50 V6 R4 50 V5 R5 50 RECEIVER C20 0 POWER NETWORK LISN L7 100nH C15 500pF C19 2n 0 MACHINE TOOL 1n 0 Simulation of the LISN

24 Conducted Emission 24 Capacitive Foil Probe (CFP) - CRYPTE (ONERA) analysis & simulation L11 2.5uh R18 2 L8 L9 16uh 16uh R1 R POWER NETWORK T34 in1 out1 in2 out2 in3 out3 T3coupledX L12 1.5uH L13 1.5uH L14 1.5uH C21 0.1uf R C23 0.1uf R C24 0.1uf R21 50 STABILISATION NETWORK 0 CAPACITIVE FOIL PROBE (CFP) R28 50 C25 100pf 0 RECEIVER T19 in1 out1 in2 out2 in3 out3 T3coupledX C19 2n 0 C9 2.2uf L10 2mH K K1 K_Linear COUPLING = mH L20 MACHINE TOOL R C10 2.2uf C12 4.7nf L30 2mH K K2 K_Linear COUPLING = 0.99 L40 2mH C11 4.7nf C20 1n V4 R6 50 V6 R4 50 V5 R5 50 Simulation of the CFP lumped model

25 Conducted Emission 25 Capacitive Foil Probe (CFP) - CRYPTE (ONERA) analysis & simulation L8 16uh R1 6 L11 2.5uh R18 2 L9 16uh R2 6 T34 in1 out1 in2 out2 in3 out3 T3coupledX L12 1.5uH L13 1.5uH C21 0.1uf R C23 0.1uf R20 50 CAPACITIVE FOIL PROBE (CFP) OPEN CIRCUIT T35 R26 100MEG FOIL in1 out1 in2 out2 in3 out3 in4 out4 T4coupledX R27 50 RECEIVER T19 in1 out1 in2 out2 in3 out3 T3coupledX C9 2.2uf L10 2mH K K1 K_Linear COUPLING = mH L20 R C10 2.2uf C12 4.7nf L30 2mH K K2 K_Linear COUPLING = 0.99 L40 2mH C11 4.7nf V4 R6 50 V6 R4 50 V5 R POWER NETWORK L14 1.5uH 0 C24 0.1uf R C19 2n 0 MACHINE TOOL C20 1n STABILISATION NETWORK Simulation of the CFP transmission line model

26 26 Conducted Emission Capacitive Foil Probe (CFP) - CRYPTE (ONERA) analysis & simulation 150 COMPARISON LISN - CFP Effect of CFP modeling: Transmission Line model vs. Capacitor lumped model (network impedance stabilised; MT filter installed) LISN Received Voltage (dbuv) CFP: C lumped model CFP: TL model ,001 0,01 0, Frequency (MHz)

27 Overview 27 Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions

28 28 Radiated Emission The main problems for in-situ measurements for radiated emission are: the lack of space to perform adequate measurements using antenna s the background noise in an industrial environment Therefore, an alternative methodology has been developed, by putting a simple wire over the machine. This wire acts as an antenna, and is able to capture radiated emissions. The problem is to identify and define a correlation factor (or antenna factor or K-factor) for this test-wire method.

29 Radiated Emission 29 Definition of the problem

30 Radiated Emission 30 Definition of the problem - Basic concept by use of GTO

31 Radiated Emission 31 Definition of the problem - Basic concept by use of GTO LABEIN CETIM SIEMENS MEAN VALUE ANTENNA METHOD - TEST WIRE METHOD COMPARISON: CETIM, LABEIN, SIEMENS GTO with Cu-plate not mounted, in semianechoic chamber Proposed K-factor (initial) Proposed K-factor (new) 20 Difference (db/m) Frequency (MHz)

32 Radiated Emission 32 Definition of the problem - Basic concept by wire simulation

33 Radiated Emission 33 Definition of the problem - Basic concept by wire simulation

34 Overview 34 Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions

35 35 Immunity Testing It has been found that two different interferences are important concerning the immunity of machines Effects by radio transmitters, simulated by CW signal injection Effects due to transients, simulated by EFT and external ESD Most machines have only a few outside connections: Connection to a power mains network Connection to a LAN or data network Construction of the machine is normally a metal chassis or even closed cubicle, and cable layout near the metal GND reference can easily be done EMC assessment will show that all subparts, subassemblies and components are CE marked, and that final testing is only intended for final control of the machinery Simple alternative methods might be used

36 Immunity Testing: radiated immunity 36 Bulk Current Injection instead of Radiated immunity testing, in the range from 1 MHz upto 1 GHz (and above) on all external cabling. This avoids also the perturbation of the spectrum. Injected current was found to be about 1.5 ma/ 1 V/m fieldstrength

37 37 Immunity Testing: radiated immunity Po w er for 40 db am plifier to g enerate 3V on cab ling 40,00 30,00 20,00 Pin (dbm) 10,00 EM 101 EF T Folie 0,00-10,00-20, Frequentie (M Hz) Comparison of BCI clamp (EM 101), EFT capacitive clamp and CFP probe for conducted immunity tests

38 38 Immunity Testing: radiated immunity Bulk Current Injection instead of Radiated immunity testing, in the range from 1 MHz upto 1 GHz Injected current following MIL Std 461E

39 39 Immunity Testing: radiated immunity Bulk Current Injection instead of Radiated immunity testing, in the range from 1 MHz upto 1 GHz Injected current following Ford Motor Co.

40 Immunity Testing: radiated immunity 40 Bulk Current Injection instead of Radiated immunity testing, in the range from 1 MHz upto 1 GHz: Measuring setup