The Austrian company Sandvik Mining and Construction G.m.b.H. exports its mining and tunneling machines all over the world. But prior to that, the impressive high-performance products undergo extensive testing in Zeltweg in Upper Styria - under real grid conditions. A test bench solution developed by ABB for simulating different voltages and frequencies for a wide variety of grids makes this possible.
The cable-driven Borer Miner SANDVIK MF460 is a giant. With its rotating cutting heads, it effortlessly cuts through rock over a width of six meters and automatically transports the extracted material to the connected conveyor belt. The integrated mining system of the Swedish Sandvik Group is manufactured in Austria. Over more than ten years, the facility in Zeltweg has developed the extraction machine in XXL format in close cooperation with the multinational mining company BHP. Four of these underground systems will be used in its new potash mine in the Canadian province of Saskatchewan from the end of 2026, potentially producing over ten million tons of potassium carbonate per year.
Ready for the world market
High-performance products such as the SANDVIK MF460 stand for top quality and reliability. Before Sandvik disassembles the oversized machines into individual parts, ships them and assembles them on site at the customer's premises, comprehensive final inspections are carried out at the Zeltweg site. The problem: Many of the mining companies are located in countries whose electricity grids have different frequencies and voltages than those in Austria. Canada is one of them. In order to be able to fully test the cutting tools driven by electric motors and other installed electronic components, the real grid conditions are quickly simulated in the test benches.
Stepless simulation
Since June 2023, Sandvik has been using a switchgear system specially configured by ABB for this purpose. At its heart is ABB’s standard ACS880 frequency converter. The alternating current from the public grid is fed in via a transformer. The connected frequency converter transforms the standard Austrian frequency of 50 Hertz into an output with variable frequency and voltage. There, a second transformer passes on the correct parameters to the Sandvik test bench. If the technicians then connect the machines for their tests to the "socket" in the factory building or outside, alternating current flows at 60 hertz and 1.1 kV or 4.16 kV - just like in the Canadian grid.
Full power despite high energy currents
Erwin Dulnigg, who as Plant Manager is responsible for the energy supply of the entire plant in Zeltweg and all associated investments, is completely enthusiastic about the new solution: "With the ABB system, we can start up our machines for the final tests at different frequencies and voltages. And this despite the high currents during direct start-up”, as he explains. "ABB was the only provider that was able to fully meet our requirements." Another plus: The ABB solution is based on standard products. "It took just six months for the new switchgear to be installed on our factory premises," emphasizes Dulnigg.
In the past, Sandvik used a rotating forming set consisting of a motor and diesel generator for the simulation. "Both the high level of maintenance and the noise and exhaust pollution severely impaired the work of our technicians," recalls the plant manager. The old setup was neither particularly energy-efficient nor environmentally friendly. To minimize the potential danger of the fuel tank, Dulnigg and his team had to invest in additional infrastructure.
Low noise and energy efficient
With the new switchgear from ABB, Sandvik Mining and Construction G.m.b.H. has now found a solution that is both economical and low-emission. The entire technology is installed in two containers. The drive cabinets are lined up close together inside. To prevent the water-cooled frequency inverters from overheating while the system is in operation, an air/water heat exchanger is located on the roof for cooling. With the help of ABB's Optimal Grid Control (OGC) software, the standard ACS880 IGBT power supply units can be used for various grid simulations. Originally developed to use the ABB frequency converters for shore power supply of international ships in ports, the application now supports Sandvik in the simulation of their country-specific grids.
Everything from a single source
Status monitoring and programmable logic control of the technology is carried out using the ABB AC500 PLC platform. Their control panel is attached to the Sandvik switchgear. "This means our technicians can do everything conveniently from one place," says Dulnigg. "We rarely have to go into the containers themselves." What the plant manager particularly appreciates about ABB is that the technology group supplies everything from a single source as a complete system provider – from the containers with the powerful frequency converters and transformers to the control system, cooling, fire alarm system and cabling.
Blueprint for other industries
The installation at Sandvik proves: The system configured by ABB scores highly for its high flexibility. Soon, other industries such as the metals sector or the pump industry could also benefit from the innovation. If more power is required in the future, the solution could be scaled up using a larger number of frequency inverters. ABB's container solution offers tangible benefits wherever machines with electric motors or generators need to be tested under variable grid conditions.
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Title image: courtesy of Sandvik Mining and Construction G.m.b.H.
