“Our new DC drive, the Mentor MP, is the result of several years’ research and development by Control Techniques, and now sets a new world standard for excellence in DC motor control,” says product manager Richard Smith.
Mentor MP follows in the footsteps of the well known Mentor brand that was launched as the world’s first digital DC drive in 1986. But Mentor MP also offers the same flexible control platform as Control Techniques’ intelligent AC drive, Unidrive SP.
“We believe it is the most advanced DC drive on the market, offering energy efficient operation, high motor performance and extreme flexibility in its system interfacing capabilities and onboard processing power.
“Mentor MP is an all new drive,” says Smith. “Control Techniques has invested heavily in its development.”
Are DC drives not doomed?
“Why develop an all new DC drive when the demise of DC has been forecast for many years?” asks Smith. “We believe the answer is simple. Our extensive market research shows that DC drives are here to stay and at Control Techniques we can offer customers unique benefits that arise from our global network of Drive Centres – a massive source of 35 years of accumulated experience in DC drives and automation applications. Mentor MP is an enormous step forward in virtually every respect and meets all present and anticipated DC market needs.”
Control Techniques argues that Mentor MP plays a part in promoting sustainable technology. DC motors are both efficient and robust and offer many years of service, providing good performance in a wide range of industrial processes and applications. Retaining an existing DC motor and upgrading the drive makes good environmental and investment sense to any customer’s upgrade project. It provides the opportunity to enhance the overall system performance and reliability whilst minimising problematic re-engineering and installation work; an attractive proposal in today’s economic environment.
“Mentor MP is designed with the requirements of both today and tomorrow in mind,” says Smith. “The full system integration flexibility offers three option module slots and an inbuilt field controller. The new product stringent development process employs cutting-edge design tools to ensure best performance and reliability in all of its products and Mentor MP is no exception. The simulation and modelling technology used to develop Mentor MP today simply was not available a few years ago. We have been able to investigate and test thoroughly all aspects of the design prior to launch and we know we can obtain market-leading reliability.”
An alternative to galvanic isolation
Control Techniques has a patent (pending) on a unique aspect of the Mentor MP design. Galvanic isolation between power and control is a standard feature in AC drives and, in the case of power-side failure, protects the control circuits and customer connected equipment. Other DC drives feature a form of isolation that relies on only impedance for isolation, which has limitations. Mentor MP does not. Its novel technology achieves galvanic isolation without compromising performance or reliability.
Each Mentor MP has three universal option module slots offering users unrivalled flexibility to choose from any combination of the 18 option modules available. These economically priced option modules are common across Control Techniques’ AC, DC and Servo drive ranges and include functionality extensions such as additional feedback options and expanded I/O and a powerful onboard programmable control.
The range of optional fieldbus connectivity is unique, including Profibus-DP, Interbus-S, DeviceNet, CANopen and various Ethernet protocols such as Modbus TCP/IP, Ethernet/IP and EtherCAT.
Communications gateway solutions can also be implemented easily and economically within the drive by installing two or three fieldbus option modules.
The number of option modules will increase as Control Techniques develops new solutions for its range of drives.
The Mentor MP’s standard inbuilt, field controller is all most users will ever need but an all new external field controller option, the FXMP25, provides field forcing for high dynamic applications; such as very fast reversing (eg, typical machine tool spindle applications) while a new feature allows reverse jogging control with two-quadrant drives for lower-cost systems that do not require fast reversal. In addition, Mentor MP has a field controller mode that allows itself to act as a field control for larger DC motors, where the field current can be greater than the capacity of the FXMP25.
Mentor MP uses Control Technique’s suite of well-tried and tested software tools, developed to support the programming and drive configuration of its AC drive ranges. For example CT Soft, used for drive configuration, includes a configuration wizard allowing existing Mentor users to transfer drive settings from an existing Mentor II drive to the new Mentor MP.
Existing Mentor II users will also appreciate the design results that make Mentor MP a simple retrofit, with the same mechanical footprint, main fixing centres and with power connections located in the same place as Mentor II.
SyPTLite, used already by AC drive users, can be used for simple IEC language ladder programming onboard the drive.
For high performance, cost effective automation solutions, Mentor MP offers the capability to link multiple AC, DC and servo drives together with extensive I/O, controlling PCs and operator interfaces by using CTNet to create a truly distributed control system. Each drive can house a programmable option module called SM Applications which is programmed using SyPTPro, an IEC61131-3 style programming tool with function block, ladder logic, and structured text language capability. This on-board configuration can often eliminate a standalone controller and so reduce system cost. Further option modules can be used to connect with I/O, fieldbus or Ethernet protocols for control and monitoring.
SM Applications modules can also be loaded with existing, proven, application-specific software such as crane control, winder/rewinder, flying shear and other commonly used automation functions.
“We believe that Mentor MP is the most advanced DC drive on the market,” says Smith, “and has the advantage of using the same control platform as the market-leading intelligent AC drive, Unidrive SP. With such a wide range of communications, intelligence and feedback options available, it is the natural choice for any user or OEM that wants an economic, easy-approach solution either to upgrading an existing DC installation or specifying a new one, providing significantly enhanced performance and reliability.”
John Murphy, VP strategic planning, says “Despite the common perception that DC is in terminal decline, our research suggests that the global DC drives market is still growing, albeit more slowly than the market. In fact with the credit crisis we expect continued growth over the next couple of years as engineers decide to retain perfectly good plant such as DC motor-based process lines. Control Technique’s market share in DC has steadily increased, reaching 13% in 2007. We have a target of 18% market share by 2012 – what we believe is eminently achievable.
“Perhaps our biggest market advantage comes from our global network of Drive Centres, which are able to retain, develop and share their many years of experience in DC drive automation systems. Our customers have confidence in our ability to solve their problems; this is where Control Techniques really wins.”
The all new Mentor MP covers output current ranges from 25 A to 1850 A with a single module approach – and 7400 A when paralleled - is available in 12 and 24-pulse configurations providing low harmonics. Optional keypads are offered as high-brightness LED or multilanguage LCD with plain text versions and a range of 18 plug-in option modules including SM-EtherCAT, SM-Register and SM-Applications can provide extra control, functionality and communication. Whilst smartcard technology provides parameter, PLC and motion program storage in addition to drive parameter ‘cloning’.
For more information contact Bill Tedd on +27 (0)11 462 1740, [email protected], www.controltechniques.co.za
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