Application of FGI FD500 Low-voltage Frequency Converter in Water Tank type (dual frequency conversion) Wire Drawing Machine

1.Introduction

Wire drawing machines can be classified by the drawing method into direct feed type, water tank type, etc. According to the thickness of the wire, they can be further divided into large drawing machines, medium drawing machines, fine drawing machines and micro drawing machines, etc. All of them consist of two parts: wire drawing extension and wire winding. To increase the output, quality and reduce costs of cables, wire drawing machines are generally changed to dual frequency conversion or multiple frequency conversion constant tension control. However, at present, most frequency conversion synchronous control methods generally adopt the control mode of external PID controllers. The disadvantages of this method are: The control parameters of PID controllers are difficult to debug, expensive, prone to damage, and there are problems of attenuation and drift during the transmission of analog quantities. The maintenance and repair costs are relatively high.

2.The working principle of the water tank wire drawing machine

Take the water tank type double frequency conversion wire drawing machine as an example to illustrate the control principle of the wire drawing and winding machine. This principle is also applicable to other constant tension control equipment. The direct feed wire drawing machine differs from it only in reducing the part of calculating the coil diameter.

To ensure that the tension of the wire drawing machine, especially the micro-drawing machine, remains constant during the winding and unwinding process and that the winding and unwinding are synchronized without breaking the wire, the frequency of the wire drawing main machine is generally used as the feedforward frequency of the winding slave machine. As the diameter of the winding reel increases, to maintain a constant tension during winding and unwinding, the output frequency of the winding machine needs to be continuously reduced. The output frequency of the winding machine is inversely proportional to the diameter of the reel. It is generally composed of unwinding rollers, main machines, stretching dies, tension rollers, rewinding rollers and wire laying machines, etc.

3.Requirements for process transformation

(1) When threading low-frequency point movements, there should be sufficient torque, a fast response speed, and no jitter or tremor.

(2) When starting or stopping the main unit, no disconnection is allowed. In case of a disconnection fault, an alarm should be raised immediately and the machine should be stopped urgently.

(3) The operation should be smooth. During normal operation, the swing rod must not collide with the upper and lower limit positions.

(4) Keep the line disconnected in synchronization when the machine stops.

4.Features of FD500 Low-voltage Frequency Converter

(1) The unique automatic calculation function of the roll diameter coefficient

As the winding diameter of the winding machine keeps increasing, the output frequency of the winding machine needs to be continuously reduced. The FGI FD500 series frequency converters are specially equipped with a winding diameter calculation function inside, which dynamically, in real time and automatically calculates the current winding diameter of the winding machine to achieve a constant tension winding effect with changes.

(2) Increment of the roll diameter coefficient K

During operation, when the tension balance bar deviates from the center position, the automatic calculation function of the roll diameter coefficient K1 is activated. To ensure the tension stability at different speeds of high, medium and low, different position deviations of the pendulum rod correspond to different increments of the roll diameter coefficient K. The change rate of the roll diameter varies among different systems. The accurate calculation of the roll diameter is achieved by adjusting the increment of K.

(3) Roll diameter reset (Manual/Automatic)

At the same linear speed, the output frequencies of the winding machine at full diameter and empty diameter differ greatly. To synchronize the linear speeds of the winding machine and the main machine, the winding diameter needs to be reset when the winding is changed. When the automatic resetting function of the coil diameter is used, the coil diameter coefficient K automatically resets after each shutdown. When there is a power outage or an emergency stop, the manual coil diameter reset function should be used, that is, the external multi-functional terminals (X1 to X5) are defined as the coil diameter reset terminals.

5. Transform the schematic diagram scheme

Wiring instructions:

(1) The jog switch is connected to the X3 terminal of the main unit (the factory value is forward rotation for jog).

(2) The external terminal start switch is connected to the main unit and the wire winding machine X1 (default forward rotation).

(3) Connect the wire drawing speed potentiometer to +10V, AI2 and GND of the wire drawing machine (main unit).

(4) Connect the analog output terminals A0 and GND of the main unit to the terminals AI2 and GND of the wire winding machine.

(5) The potentiometer of the tension rod is connected to the +10V, AI1 and GND terminals of the FD500 series low-voltage frequency converter.

6.Tag

Using FGI wire-drawing machine dedicated FD500 series of low-voltage inverter without swinging rod double frequency wire drawing machine control system, after the actual use of the customer, the stability of the tension, easiness of parameter Settings, the stability of the system are obtained the customer approval.