Application of V260 series inverter communication control in the straight wire-drawing machine

Abstract: This paper introduces the successful application of V260 series product in the straight wire-drawing machines. Relying on the high accuracy PID algorithm and equipped with PLC  programme designed by SUNFAR, V260 product strengthens the stability of oscillating bar between the rollers, reduces the break rate and improves speed and efficiency.
Keywords: V60 inverter, Sunfar, straight wire-drawing machine

I. Introduction
       Metalware is an important part in the metallurgical industry, yet a vulnerable part in China because the obsolete electric equipment hinder the development. Straight wire-drawing machine is a general one in the metal processing as well as an advanced and promissing one. The wire-drawing is realized by the F-D system in the past, however, with the development of technologies and popularizing of inverter, inverter begins to be used on a large scale and realize the function of automatic operation, closed-loop control and production through connecting to the PLC.
       The effect is obvious to use inverter to control the straight wire-drawing machine. The range of adjustment is 30:1 in the ordinary working time, at the same time, provide more than 1.5 times rated torque under 5% rated rotating speed.
       This paper set the example of a factory that produces stainless steel wire to explain the process and effect of inverter.

II. Process requirement
       This machine mainly draws the stainless steel wire with the length of entering wire 5.5 mm, out wire 2.82mm after 4 steps of drawing mold function and the highest speed up to 5m/s under the 100Hz of inverter running. There are six drums whose diameter up to 600mm in the drawing part and the cylinder oscillating bar used to inspect position is installed between the drums which can be detected the position of swing arm through displacement sensor. When the speed difference of two rollers is big, the pressure generated by the wire rod on the cylinder will pushes the swing arm to move down,, increase the preceding PID output , stack into main speed and control the constant tension of steel wire entering to the mold. The rolling part adopts spool to wind up and the system should automatically revise given frequency according to the change of rolling diameter and realize the speed consistency through roller adjustment.

The main requirements:
Forward, reverse and jog function is required in every step
Forward linking and backward linking function
Mold hopping is needed and automatic calculate the system frequency ration
The highest running speed up to 5m/s under the frequency of 100H
Automatic record the distance and weight, when the required quantity is realized, automatic shut down
Stable acceleration and deceleration with no large fluctuation
Steady running and break-wire detection, warning and shutdown

                                                Control process


III. Solution and debugging

1.configuration of the system

 Name                             specification                                   number
PLC                                 FX3U-80M                                           1
Touch screen                Weinview 10 inches                                 1
485BD                             FX3U-485BD                                        2
Inverter                           V560-4T0300                                      2
Inverter                         V560-4T0220                                        2
Inverter                             V560-4T0150                                    1
Expansion card 1         Simple communication adapter card               1
Expansion card 2         Straight draw wire expansion card                 1
Switch power supply                                                                   1
button                                                                                    some
relay                                                                                       some


2.solution and wiring
       According to the set of human-computer interface and the machine drive ratio, the system calculate every given speed in “N”segment including subordinate drawing, master drawing, and rolling on the basis of equal volume per second of straight draw wire machine to send the result to inverter by the communication and the latter slightly adjust it via the signal feedback by oscillating bar to realize the tension constancy in every step. PLC integrates the function of forward linking, backward linking, mode-hopping and break-detection.,etc.
The following is part of wiring:

3.Logical requirements
       There are three logical relationships between the first machine and rolling. Apart from the function of jog forward, reverse running, the first machine has backward linking function and the rolling part with forward linking. Four logical relationships in the second step from subordinate drawing to master drawing, they are jog forward, jog reverse, forward linking, backward linking. For example:
3#jog forward: 3# closed forward jog terminal

3#jog reverse:3#closed reverse jog terminal

       Apart from the rolling, any machine in the system can be mode hopped( at least one machine as master machine in the main drawing and subordinate drawing). The system automatically calculate the speed ratio between the master and left and send it to inverter when the human-computer interface choose one or more machine to mode hop.

Level-N subordinate parameter setting
F0.0.07=7                 Parameter initialization and configuration
F0.2.25=17                    Channel 1 setting as communication setting
F0.2.26=23                   Channel 2 setting as PID output
F1.0.03=2.00                  Acceleration time of 2s
F1.0.04=2.00                  Deceleration time of 2s
F1.0.09=5.00                  Jog acceleration time of 5s
F1.0.10=5.00                 Jog deceleration time of5S
F3.0.12=6                     DO1 as failure output
F3.0.21=26                      Break wire detection
F7.0.08=60.0                    PID setting
FC.0.01=0.55                          “P”of PID
FC.0.02=20                             “I”of PID
FC.0.03=0.2                        Channel 2 coefficient 1
FC.0.06=0.6                        Channel 2 coefficient 2

Main drawing parameter setting
F0.2.25=17                          Freq. Setting source as communication setting
F1.0.03=2.0                         Acceleration time of 2S
F1.0.04=2.0                         Deceleration time of 2S
F1.0.09=5.00                       Jog acceleration time of 5S
F1.0.10=5.00                       Jog deceleration time of 5S
F3.0.00=7                            DI1as running signal
F3.0.01=5                            DI2as forward jog signal
F3.0.02=6                             DI3as reverse jog signal
F3.0.03=14                           DI4as EMS signal
F3.12=6                               DO1as fault output

Rolling parameter setting
F0.0.07=7                      Parameter initialization and setting
F0.2.25=17                    Channel 1 setting source as communication setting
F1.0.03=2.00                  Acceleration time of 2S
F1.0.04=2.00                  Deceleration time of 2S
F1.0.09=5.00                  Jog acceleration time of 5S
F1.0.10=5.00                   Jog deceleration time of 5S
F3.0.12=6                       DO1as fault output
F3.0.21=26                     Break detection
F7.0.08=60.0                   PID setting value
FC.0.01=0.55                   “P”of PID
FC.0.02=20                      “I”of PID
FC.0.03=0.2                      Channel 2 coefficient 1
FC.0.06=0.6                      Channel 2 coefficient 2


V. Summary
       It is considered that the solution of V260 high-performance vector inverter and PLC communication reduce the break rate to a large extent by the system optimization, smooth startup and shutdown. Compared with the DC driving system, the efficiency and rate of power saving are also obviously improved. The fact proves that the system is both stable and simple for fault inspection.