Alimentation électrique pour les machines
Plusieurs lignes d'alimentation du réseau de moyenne tension se trouvent sur le site de l'usine de Schweinfurt. Elles alimentent le poste de transformation, qui compte un peu moins de 100 transformateurs, et ceux-ci alimentent à leur tour une trentaine de tableaux de distribution principaux à basse tension, qui fournissent l'alimentation électrique aux machines de production de l'usine. « La sécurité et la fiabilité de l'alimentation électrique sont particulièrement importantes pour nous », explique Julian Kübler, responsable du contrôle des transformateurs moyenne et basse tension de l'usine Schaeffler de Schweinfurt. Des disjoncteurs isolent séparément les sorties des charges électriques des systèmes. Chaque disjoncteur est logé dans une armoire de commande dans son propre réseau. Pour les charges de faible puissance, plusieurs petits disjoncteurs sont parfois montés dans un ensemble. Un système typique se compose de deux à trois régions avec 15 à 20 réseaux d'une puissance totale allant jusqu'à 2 000 kVA.
Contrôle à distance des disjoncteurs
Lors de l'installation des systèmes basse tension en 2015, une alarme de dysfonctionnement a également été incluse. Kübler décrit ainsi les inconvénients de l'ancien système : « Auparavant, les systèmes ne pouvaient déclencher qu'une défaillance collective, qui était ensuite transmise au bureau de sécurité de l'usine. » Un circuit en boucle transmettait alors l'alarme à tous les disjoncteurs, de sorte qu'il était impossible de déterminer à distance quel débit était réellement affecté. Dans un premier temps, pour déterminer précisément quel disjoncteur a déclenché la panne, les sorties de messages de tous les disjoncteurs ont été envoyées à une armoire de commande supplémentaire située à proximité de l'installation. Un contrôleur a traité les signaux et transmis les messages correspondants au centre de contrôle. « Le coût du câblage de cette solution était toutefois extrêmement élevé », explique Kübler, « nous avons donc cherché des alternatives. »
Les employés de Schaeffler du service des installations de l'usine ont touché le gros lot avec WAGO. Le matériel tel que les coupleurs de bus de terrain et les modules d'E/S du système modulaire WAGO 750 I/O-SYSTEM permet une solution nettement plus élégante pour le traitement des messages d'erreur. En outre, chaque baie d'armoire de commande du système a été équipée d'un coupleur PROFINET. Celui-ci comprend un module d'entrée numérique à 16 canaux, qui dispose ainsi d'une capacité suffisante pour évaluer en détail tous les messages du disjoncteur. Un contrôleur central fonctionne comme maître dans PROFINET et lit les signaux du coupleur PROFINET; le traitement supplémentaire et la liaison avec le centre de contrôle fonctionnent comme auparavant. L'utilisation du coupleur PROFINET de WAGO présente un avantage essentiel pour Kübler : « Nous n'avons qu'à connecter les coupleurs avec des câbles de raccordement d'un réseau à l'autre. Comme nous utilisons une topologie en anneau, le système fonctionne même si un câble de raccordement est interrompu. » Les câbles sont connectés directement par des canaux internes dans l'armoire de commande. Un câblage coûteux à travers le plancher surélevé du système n'est plus nécessaire. Étant donné que les lignes de commande et les câbles d'alimentation sont acheminés des disjoncteurs aux charges via le compartiment commun de connexion des câbles, les sorties respectives devraient être déconnectées de l'alimentation pour que les câbles de signal puissent être posés.
Alertes – détaillées et à toute heure
Les employés peuvent contrôler à tout moment l'état de tous les disjoncteurs depuis le centre de contrôle, installé dans l'atelier de maintenance. L'état de l'ensemble de l'alimentation électrique y est visualisé de manière transparente. Le nouveau système de signalisation des pannes, qui a été installé jusqu'à présent dans trois des systèmes à basse tension, offre beaucoup plus de fonctions que la solution précédente. En cas de panne, les employés de maintenance savent quel disjoncteur a été déclenché et quel dysfonctionnement se trouve à quel endroit. Le centre de sécurité reçoit également des messages d'erreur plus détaillés et peut ainsi fournir des renseignements importants aux travailleurs de service sur appel avant qu'ils n'arrivent dans l'installation. « De cette manière, nous pouvons augmenter la sécurité de notre alimentation électrique basse tension, et donc le temps de fonctionnement de nos systèmes de production », déclare Kübler avec satisfaction.
Facilité de mise à niveau et possibilité d'extension
Outre la facilité de câblage, un autre avantage décisif du coupleur PROFINET de WAGO réside dans ses dimensions compactes. Kübler explique : « Nous avons pu les intégrer sur les rails DIN existants dans les différentes armoires de commande avec un minimum de modifications. » Les composants de WAGO peuvent être intégrés dans les systèmes électriques existants avec la même facilité. Le système peut être étendu de manière flexible. La commutation des disjoncteurs, qui sont actuellement commandés à partir du centre de contrôle ou sur place par des opérations à distance, via la commande centrale, fait partie des projets à venir. Pour ce faire, il suffit d'ajouter au coupleur PROFINET un seul module de sortie numérique correspondant. « La commutation à distance présente l'avantage que l'opérateur n'a pas à se tenir directement devant l'armoire de commande en cas de court-circuit et d'arc interne qui peut se produire », explique Kübler.
par Frank Sünkel | 12-10-2016
Photos : Anand Anders/vor-ort-foto.de
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