SmartGen’s blog

From Jan.21 to Jan.31, 2020

Back to work on Feb.1

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—Continuous improvement without limits

With the approaching of the New Year, we bid farewell to the special 2020 and welcome the hopeful 2021.

With the active participation of all departments, the lean improvement project of SmartGen has also celebrated its fifth phase.

The 8 projects in this competition all focus on the QCDSM (Quality, Costing, Deadline, Safety, Morale) of management objectives, with many highlights and benefits, which has injected vitality and power into the continuous lean development.

Two winning projects are:

1. Shell seal improvement project of R&D Center: The material is changed from solid to liquid, and the production and assembly method is changed from manual to automatic, which improves the degree of automation, conforms to the characteristics of Industry 4.0 and applies the TRIZ theoretical knowledge. This project not only improves production efficiency, but also reduces costs while ensuring the quality.

2. Order placement timeliness improvement project of Production Center: By reorganizing and optimizing the physical flow and value flow, the timeliness of production order placement is greatly improved. This improvement will not only speed up the overall inventory turnover, but also ensure the delivery time of users in a timely and fast manner.

Lean is the only way to practice the company’s strategy. We will closely embrace the company’s values of “Innovation, Focus, Lean-Better”, start from the heart and ourselves, and continue to build the innovation and improvement culture of SmartGen!

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1562TEU Container Ship “Maogang Shanghai”

On January 13, 2021, the 1562TEU container ship “Maogang Shanghai”, which was manufactured by Zhejiang Hexing Shipyard and classified into CCS, was successfully launched into the water. At present, it has been successfully towed to the anchorage for the next stage of equipment commissioning. The ship power station uses three 400kW diesel gensets as the main genset (the original engine is Yuchai YC6TD655L-C20 marine ECU diesel engine), the total capacity of the power station is 1200kW and 500kW shaft genset is used under navigation. SmartGen provides the ship with one-stop power station management solution from engine control to main switchboard control.

Schematic diagram of SmartGen marine engine intelligent control and power station power management solution

In order to promote the reliability and automation of this ship’s automatic power station management system, this ship’s main genset is equipped with MGCP100B-2 diesel engine control box developed by SmartGen for marine ECU to realize the automatic start/stop of main genset, engine safety protection and ECM parameter monitoring functions. Its main control unit applies HMC9000A engine controller. The control box is equipped with a built-in HEP300 electronic potentiometer, which can convert the passive digital speed signal from the switchboard into a 0~5V signal with higher precision to achieve higher precision load adjustment. The HRM3300-3 remote control box with the same operating interface as the local control box, is installed on the alarm detection platform.

Meanwhile, the main switchboard adopts the multi-master power management system built by SmartGen HMC6 power management controller to realize the on-demand automatic scheduling and real-time protection of 3 main gensets + 1 shaft genset + 1 emergency and mooring genset, which greatly improves the power supply reliability of the power station.

Since SmartGen mature products with full intellectual property rights and CCS certification are used from diesel engine control to power management module of the main switchboard, the whole system follows the same design style, with more friendly HMI, easier operation and more efficient crew training.

During the commissioning process of the power station, SmartGen’s on-site service personnel worked together with the project management personnel of Hexing shipyard, ship owner representatives, genset manufactures and main switchboard manufacturers, to ensure that the power station passed the acceptance of the CCS with high standard. This is another successful case of SmartGen marine control products in high-end marine application field in 2020.

Topology of SmartGen marine engine intelligent control and power station power management solution

Main switchboard of power management system built by SmartGen HMC6 power management controller

3 main gensets with SmartGen MGCP100B-2 diesel engine control box

SmartGen HRM3300-3 remote control box installed on the alarm detection platform

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Product highlights:

1. Wide working temperature range (-40°C~+70°C), suitable for high altitude, alpine regions;
2. Suitable for non-breaking, one-breaking and two-breaking switches;
3. With RS422 isolated communication port, can choose RS422 or RS485 communication, applies ModBus-RTU communication protocol;
4. 132×64 LCD with backlight, optional Chinese and English display;
5. DC9-35V continuous power supply, with DC reverse connection protection function;
6. Two-way DC power input (DC power redundancy design);
7. With real-time clock, event log (50 pieces), scheduled start function;
8. Suitable for 3-phase 4-wire, single phase 2-wire, 2-phase 3-wire;
9. Personalized design and simple wiring;
10. D-type USB port;
11. IP65 protection level.

Controller Rear Panel

Typical Wiring Diagram

SGQ-N/T Application Diagram

Breaker (ACB) Application Diagram

Overall Dimensions and Cutout

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——Application of construction machinery product HEM4100

Rotary drilling rig, belonging to construction machinery, is a special construction machinery for bored pile drilling operation. It is widely used in municipal construction, highway and railroad bridges, high-rise buildings and other foundation construction. With different drill bits, it is suitable for drilling in various geologies such as clay, silt, sand, mucky soil, artificial backfill and stratum containing some pebbles and gravels, and can be adapted to the construction of weathered rock layers.

At present, the construction machinery engine is in the stage of updating the national Ⅱto nationalⅢemission standards. In this case, the nationalⅡengine is replaced by nationalⅢengine. SmartGen’s construction machinery product HEM4100 controller is used for transformation. The rotary drilling rig uses ECU engine as the power source. This case applies CAN J1939 of HEM4100 to communicate with engine ECU and achieves start and stop of HEM4100 through its start and stop button. The throttle (i.e. speed) is flexibly controlled by the throttle pedal device, and the engine speed, battery voltage, oil pressure and engine temperature are monitored in real time by HEM4100 to achieve normal operation of the rotary drilling rig.

Site Pictures

HEM4100 Wire Connection

HEM4100 Panel

Throttle Pedal

Rotary Drilling Rig Engine

Rotary Drilling Rig

HEM4100 Front Panel

HEM4100 main functions:

1、Support relay, CAN BUS speed adjustment.
2、USB, RS485 communication ports.
3、6-way analog suit for multi-type sensors.
4、Event log, maintenance reminder.
5、Applies to engine control systems like water pump, beacon, air compressor, construction machinery and so on.

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Application of HMC9000S+AIN16-C+AIN16-PT+HRM3300

About 30 nautical miles away from a costal port in the beautiful Zhanjiang city, Guangdong Province, there was a huge ship of nearly 10,000 tons sand pumping ship. The two 12-cyclinder water pump engines are controlled by HMC9000S, and the 12 cylinder temperatures of the engines are detected by the expanded analog input module AIN16-PT. The temperature of 8 shafts is detected by the expanded analog input module AIN16-C, and the shaft temperature signal is converted from PT100 to 4~20mA current type signal through the temperature transmitter to the AIN16-C. The AIN16-C then transmits it to the diesel engine controller HMC9000S through CANBUS (EXPANSION) communication, and finally displays the real-time temperature and protection of the shaft. HMC9000S transmits the engine information to the remote control module HRM3300 in cab through CANBUS (REMOTE) communication, and can also control engine start/stop remotely through HRM3300.

Project Control System Introduction

HMC9000S engine controller: can be widely used in marine emergency units, main propulsion units, DG units or water pump units. Its remote monitoring module interface enables remote monitoring, which can remotely control engine start, stop, etc.

HMC9000S

AIN16-PT Analog Input Module—16-way PT100 Sensor Input Module

AIN16-C Analog Input Module—16-way 4~20 mA Sensor Input Module

HRM3300 remote control module suits for the remote monitoring of HMC9000S engine controller

Typical Application of Marine Controller Communication

 

Site Pictures

Sand Pumping Ship

HRM3300 in Cab

Staff Operating HRM3300

Water Pump Engine

Water Pump Engine Cylinder Temperature

Water Pump Engine Main Shaft Temperature

PT100 to 4~20mA Temperature Transmitter

HMC9000S engine partial parameters

Common Fault Analysis:

1. HMC9000S and AIN16 communication failure:
Fault cause:
1.1 CAN H and CAN L of CANBUS (EXPANSION) communication are reversed;
1.2 CANBUS (EXPANSION) communication did not short circuit the CAN L and 120 Ω matching resistor on the controller;
1.3 If the distance of CANBUS (EXPANSION) communication line is too long, SGCAN300 relay conversion module (MSC or RS485 communication to optical fiber) should be added.
2. Inaccurate display of temperature or pressure sensor:
Fault cause:
2.1 Sensor curve setting is wrong;
2.2 Sensor is broken.
3. HMC9000S and HRM3300 communication failure:
Fault cause:
3.1 CAN H and CAN L of CANBUS (REMOTE) communication are reversed;
3.2 CANBUS (REMOTE) communication did not short circuit the CAN L and 120 Ω matching resistor on the controller;
3.3 If the distance of CANBUS (REMOTE) communication line is too long, SGCAN300 relay conversion module (MSC or RS485 communication to optical fiber) should be added.

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New Year’s Day Holiday

Jan.,1st-Jan.,3rd 2021

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2020 is destined to be an extraordinary year, there are too many unforgettable moments burned in our hearts;

The country’s economic, social and livelihood development suffered a major setback in 2020 due to the impact of the coronavirus;

In 2020, all rural impoverished population under the current standard have been out of poverty;

In 2020, Chang’e 5 return capsule carries lunar samples back to the earth;

……

2020 is coming to an end. Let’s review the experience accompanied by SmartGen.

2020 will soon pass, this year has left us too many special memories. Let’s say goodbye to the extraordinary 2020 that we have experienced and persevered together, and let’s welcome the new 2021 together!

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The customer uses 8 Cummins engines with SmartGen parallel controller to achieve multi-unit parallel power generation for foreign rental.

Engine Model: Cummins 6ZTAA13-G4
Controller Model: SmartGen HGM9510
Engine GOV Model: S6700H
Generator AVR Model: AS440

HGM9510 controller applies 32-bit microprocessor technology to realize precise parameters measuring, fixed value adjustment, timing and threshold setting and other functions. A majority of parameters can be configured from controller’s front panel and all parameters can be configured by USB (or RS485) port to adjust via PC .

Utilizing the GOV (Engine Speed Governor) and AVR (Automatic Voltage Regulator) control functions, the controller is able to synchronize and share load automatically. It can be used to parallel with other gensets equipped with HGM9510 controller.

HGM9510 realizes multi-unit synchronization and load distribution by adjusting engine GOV S6700H and generator AVR AS440. Three-phase voltage monitoring module HVD100 collects mains voltage to start genset automatically in case of mains abnormal. It is equipped with battery charger BAC06A-24V to achieve automatic charging function. With simple connections, easy operation and direct parameter modification via panel, it can meet the application of different parallel mode.

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With the rapid development of industry, people have higher and higher requirements for power supply reliability. In some important occasions, dual-power switching cannot meet the requirements, so it is necessary that reliable switching between the three powers to ensure the power supply continuity. As the core control part of three-power switching, three-power ATS controller is indispensable and plays a vital role. In order to meet the switching scheme of different switches and applications, SmartGen has developed HAT832 and HAT833 three-power ATS controller to meet the market demand.

HAT832 is used for Three Power switching system consisting of two ATS switches, which can be applied to Mains-Mains-Gen, Mains-Gen-Gen and other system types.

1.Can be used for various PC-level switches;
2.Collect and display 3-way 3-phase voltage, frequency and phase sequence;
Collect and display load active power, reactive power, apparent power, power factor and current;
3.S1/S2/S3 priority arbitrary setting;
4.Power system type can set as Mains-Mains-Mains, Mains-Mains-Gen, Mains-Gen-Gen;
5.Voltage transformer ratio function;
6.Black box function, which can cycle record 5 pieces of log and each log contains 60 groups of data including switch status detailed data of 50s before and 10s after switchover;
7.Can control two gensets to realize cycle run, master-slave run and balanced run;
8.Genset scheduled run/scheduled not run function that can set as run once a day/week/month.

HAT832 Project Application (S1 Mains-S2 Gen-S3 Gen)

HAT833 is used for Three Power switching system consisting of three ACB switches

1.Collect and display 3-way 3-phase voltage, frequency and phase sequence;
2.Collect and display load active power, reactive power, apparent power, power factor and current;
3.S1/S2/S3 priority arbitrary setting;
4.S1/S2/S3 master input, highest switching priority when input port is active;
5.Input ports forced manual mode and auto mode;
6.Auto transfer/restore input, auto transfer/restore when active, auto transfer, non-restore when inactive;
7.Elevator control output, output before load outage or switch transfer, is used to control the running elevator to stop at the nearest floor until the switch transfer is completed;
8.Closed output of 3-way ACB switches;
9.Switch is transferring, output during the switch transfer process;
10.Voltage transformer ratio function.

HAT833 Project Application (S1 Mains-S2 Mains-S3 Gen)

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