FD300 Series Empowers Intelligent Rubber Manufacturing

The open mill serves as a core mechanical device in processing polymer materials like rubber and plastic. It finds wide application in the production of tires and various rubber/plastic products. It is also key equipment for the mixing process in rubber tire plants.

The speed control accuracy of the open mill directly affects mixing quality and efficiency. As the core control component of its drive system, the frequency converter can actively adjust output frequency based on the process. This enables stepless speed regulation for the open mill, meeting the speed requirements for different materials and processes.

In this project, the FGI FD300 series frequency converter successfully broke reliance on foreign brands. By precisely replicating the original controller's command words, feedback words, and relevant data addresses, it achieved seamless replacement of the original international brand frequency converter on the production line. This solution is fully compatible with both single-drive and dual-drive equipment. It requires no modification to the original production line and no adjustment of any process parameters, greatly reducing the customer's upgrade costs.

The product integrates Profinet and CAN industrial communication technologies. It combines precise vector control with adaptive energy-saving algorithms. This allows it to easily handle complex working conditions like high mixing loads and precise speed control during vulcanization. It ensures precise and controllable roller speed and provides a fast response to sudden load changes. Simultaneously, it significantly reduces energy consumption and greatly improves production efficiency.

With its independently developed domestic frequency conversion technology, the FGI FD300 series frequency converter effectively addresses key industry drive challenges. It provides reliable support for the intelligent upgrading of the rubber industry, helping enterprises build a foundation for efficient, green, and stable production.

Solution

For a rubber project in Shandong, to meet the customer's specific requirements for frequency converter equipment, the company developed a complete solution based on the FD300 series frequency converter. This involved collaborative hardware and software design and deep adaptation.

1. Seamless Communication Compatibility:The solution uses the Profinet communication protocol. Through deep parsing of the XML model, it intelligently simulates and matches device identification information (including DAP, Interface, DualPort, etc.). It precisely configures signal slots (SLOTS) and replicates the device-application relationship (AR) and communication relationship (CR). Consequently, the FD300 frequency converter replaces the original device's functional points in the host control system. This enables a smooth process flow switchover. The customer does not need to modify existing control programs or configurations.

2. Comprehensive Command and Data Correspondence:The solution involves in-depth analysis of the command word and status feedback word communication mechanisms of the original brand frequency converter. This ensures full functional compatibility. It fully interfaces with the data addresses and communication structure of the original control system. Without adjusting the original PLC program or monitoring screens, it enables remote control and real-time monitoring. This maintains continuity and consistency in system operation.

3. Enhanced Functionality and Process Adaptation:The original equipment had limitations in setting the master-slave speed difference in remote control mode. The FD300 series provides a more flexible control strategy. In remote control mode, operators can independently set the speed for a single device. In local control mode, it supports master-follower mode, where the follower tracks the master's speed in real time. This functional optimization precisely meets the process requirements in rubber processing. It offers customers a more complete solution that better fits production needs.

Field Verification

Stable and Reliable Communication:The matching hardware and software design strengthens device communication quality. It ensures no communication interruptions occur, guaranteeing continuous and stable system operation.

Strong System Compatibility:Customers can directly continue using their original control system. They can implement start/stop control of our equipment and perform real-time monitoring and adjustment of device status from remote consoles.

Flexible Operation Modes:The solution supports seamless switching between remote and local modes, as well as dual-machine speed modes. This fully satisfies the different control method requirements in rubber processing.

Relying on the FGI frequency converter replacement solution, the customer achieved significant benefits in the following areas:

1.No Extra Production Line Modifications:Using the FD300 frequency converter for direct replacement of the original equipment enables seamless integration. This saves production line modification costs and avoids capacity loss from prolonged downtime for upgrades.

2.Ensured Production Continuity:During local/remote switching, the system automatically completes the transition between single-unit mode and master-slave mode. This greatly reduces maintenance time and operator adaptation costs, ensuring an uninterrupted production flow.

3.Optimized Safety Control Mechanisms:Safety protection strategies are enhanced from both hardware and software levels, considering the characteristics of the rubber industry. This effectively prevents various potential risks such as communication interruptions, control failures, and operational abnormalities, elevating production safety.