Below is the English translation of the provided article, with key sections highlighted in bold for emphasis.
Design and Application of the 900 Series Inverter in the Winding Machine Traverse System
The winding machine and its traverse system are primarily used to ensure that materials (such as paper, film, or wire) are neatly and evenly arranged on the reel during the winding process, preventing stacking or misalignment. The following sections detail the application of the inverter, including motor selection, wiring methods, parameter settings, control logic, and the integration of PLC, HMI, or industrial PC, based on the process equipment workflow.
1. Functional Analysis of the Winding Machine Traverse System
The traverse system of a winding machine typically requires the following functions:
- Main Winding Motor: Drives the reel to rotate, completing the material winding process.
- Traverse Motor: Drives the traverse device to move left and right, ensuring even material distribution on the reel.
- Tension Control: Maintains constant material tension during winding to avoid stretching or slackening.
- Speed Synchronization: The traverse motor’s movement speed must synchronize with the main winding motor’s speed to match the material winding speed.
- Position Control: The traverse device must reciprocate based on the reel width, with left and right limit settings.
- Start/Stop Control: Controls the start and stop of winding and traversing via external signals (e.g., buttons or PLC).
- Fault Protection: Detects faults such as overload, phase loss, or overcurrent, stopping the system for protection.
A typical winding machine traverse device includes a main winding motor (driving the winding drum) and a traverse device (achieving left-right movement through a lead screw). We will use the 900 series frequency converters to control the main winding motor and the traverse motor.
2. Motor Selection and Function Assignment
2.1 Main Winding Motor
- Function: Drives the reel to rotate, completing material winding.
- Motor Selection: Based on the winding machine’s load and reel diameter, we assume a 4kW three-phase asynchronous motor (380V) is required. From the inverter model table on page 5 of the manual, we select the 900-0040G1 model (suitable for a 4kW motor, rated output current 18A).
- Control Mode: Uses V/F control mode (ideal for scenarios with significant load variations like winding machines), adjusting speed via the inverter to control winding speed.
2.2 Traverse Motor
- Function: Drives the traverse device to move left and right, achieving reciprocating motion via a lead screw mechanism.
- Motor Selection: The traverse motor typically requires less power; we assume a 0.75kW three-phase asynchronous motor (380V) is needed. From the manual’s model table on page 5, we select the 900-0007M3 model (suitable for a 0.75kW motor, rated output current 2.5A).
- Control Mode: Uses open-loop vector control mode (suitable for precise speed and direction control), managing the traverse motor’s forward/reverse rotation and speed via the inverter.
3. Inverter Wiring Design
3.1 Main Winding Motor Inverter (900-0040G1) Wiring
- Power Input:
- Inverter input terminals R, S, T connect to a three-phase 380V power supply.
- Ground terminal PE connects to the ground wire for safety.
- Motor Output:
- Inverter output terminals U, V, W connect to the three-phase input of the main winding motor.
- Control Terminal Wiring (refer to Chapter 3 of the manual, “Mechanical Installation and Electrical Connection”):
- DI1 (Start/Stop Control): Connects to an external start button (normally open contact) to start/stop the main winding motor.
- DI2 (Forward/Reverse): Connects to an external direction switch to control the main winding motor’s rotation direction (typically only forward rotation is needed for winding machines).
- AI1 (Speed Reference): Connects to a potentiometer (0-10V) or PLC analog output to adjust the main winding motor’s speed.
- DO1 (Operation Status Output): Connects to an indicator light or PLC input to output the inverter’s operating status.
- +24V and COM: Used for the power supply and common terminal of the external control circuit.
3.2 Traverse Motor Inverter (900-0007M3) Wiring
- Power Input:
- Inverter input terminals R, S, T connect to a three-phase 380V power supply.
- Ground terminal PE connects to the ground wire.
- Motor Output:
- Inverter output terminals U, V, W connect to the three-phase input of the traverse motor.
- Control Terminal Wiring:
- DI1 (Forward): Connects to the left limit switch (normally closed contact); when the traverse device reaches the left limit, it triggers to stop forward rotation.
- DI2 (Reverse): Connects to the right limit switch (normally closed contact); when the traverse device reaches the right limit, it triggers to stop reverse rotation.
- DI3 (Start/Stop Control): Linked to the main winding motor’s start/stop signal (via PLC or relay).
- AI1 (Speed Reference): Receives a PLC analog output (0-10V) to set the speed, synchronized with the main winding motor.
- DO1 (Operation Status Output): Connects to a PLC input to output the traverse motor’s operating status.
3.3 Wiring Diagram (Text Description)
Main Winding Motor Inverter Wiring Diagram:
Three-Phase Power 380V
| | |
R S T
| | |-------> Inverter (900-0040G1) Input Terminals R, S, T
PE-------------> Inverter PE Ground Terminal
Inverter Output U, V, W
| | |
U V W-------> Main Winding Motor (4kW)
Control Terminals:
External Start Button-------> DI1 - COM
Direction Switch-----------> DI2 - COM
Potentiometer (0-10V)------> AI1 - GND
Indicator Light------------> DO1 - COMTraverse Motor Inverter Wiring Diagram:
Three-Phase Power 380V
| | |
R S T
| | |-------> Inverter (900-0007M3) Input Terminals R, S, T
PE-------------> Inverter PE Ground Terminal
Inverter Output U, V, W
| | |
U V W-------> Traverse Motor (0.75kW)
Control Terminals:
Left Limit Switch-----------> DI1 - COM
Right Limit Switch----------> DI2 - COM
Start/Stop Signal (PLC)-----> DI3 - COM
PLC Analog (0-10V)---------> AI1 - GND
PLC Input------------------> DO1 - COM4. Parameter Settings
4.1 Main Winding Motor Inverter (900-0040G1) Parameter Settings
Referring to Chapter 5 of the manual, “Parameter Description,” set the following key parameters:
- F0-00 (Command Source): Set to 1 (terminal control), using DI1 to control start/stop.
- F0-01 (Target Frequency Reference Mode): Set to 2 (AI1 analog input), adjusting speed via the potentiometer.
- F0-03 (Maximum Frequency): Set to 50Hz (adjust based on actual needs).
- F0-09 (Motor Rated Frequency): Set to 50Hz.
- F0-10 (Motor Rated Voltage): Set to 380V.
- F1-00 (DI1 Function): Set to 1 (forward run).
- F1-01 (DI2 Function): Set to 2 (reverse run).
- F6-12 (Motor Overload Protection): Set to 150% (adjust based on motor rated current).
- F7-00 (Communication Address): Set to 1 (if using PLC communication).
4.2 Traverse Motor Inverter (900-0007M3) Parameter Settings
- F0-00 (Command Source): Set to 1 (terminal control), using DI1 and DI2 to control forward/reverse.
- F0-01 (Target Frequency Reference Mode): Set to 2 (AI1 analog input), adjusting speed via PLC.
- F0-03 (Maximum Frequency): Set to 30Hz (traverse motor speed is lower, adjust based on lead screw ratio).
- F0-09 (Motor Rated Frequency): Set to 50Hz.
- F0-10 (Motor Rated Voltage): Set to 380V.
- F1-00 (DI1 Function): Set to 1 (forward run).
- F1-01 (DI2 Function): Set to 2 (reverse run).
- F1-02 (DI3 Function): Set to 5 (free stop), linked with the main winding motor.
- F6-12 (Motor Overload Protection): Set to 150%.
5. Control Logic Design
5.1 Speed Synchronization Logic
- The traverse motor’s speed must synchronize with the main winding motor’s speed. Assuming the reel diameter is (D), material thickness is (t), and reel speed is (n) (rpm), the material winding linear speed is:
[
v = \pi \cdot D \cdot n
] - The traverse device’s movement speed (v_{\text{traverse}}) must match (v). Assuming the lead screw pitch is (p) and the traverse motor speed is (n_{\text{traverse}}), then:
[
v_{\text{traverse}} = p \cdot n_{\text{traverse}}
] - Thus, the traverse motor speed should be:
[
n_{\text{traverse}} = \frac{\pi \cdot D \cdot n}{p}
] - The PLC calculates (n_{\text{traverse}}) and outputs the corresponding frequency signal (0-10V) to the traverse inverter’s AI1 terminal.
5.2 Reciprocating Motion Control
- The traverse device uses left and right limit switches to control reciprocating motion:
- When the traverse device reaches the left limit, the left limit switch opens, DI1 signal fails, the inverter stops forward rotation, and DI2 triggers reverse rotation.
- When the traverse device reaches the right limit, the right limit switch opens, DI2 signal fails, the inverter stops reverse rotation, and DI1 triggers forward rotation.
5.3 Tension Control
- Tension control can be achieved by fine-tuning the main winding motor’s speed. For more precise tension control, a tension sensor can be added, with the PLC collecting tension signals to dynamically adjust the main winding motor’s speed.
6. PLC and HMI Selection and Application
6.1 Necessity of PLC and HMI
- PLC: Recommended to implement speed synchronization, reciprocating motion control, tension control logic, and communication with the inverter.
- HMI: Used for parameter setting, monitoring operating status (e.g., speed, tension, fault information), and operational control (start/stop, speed adjustment).
6.2 Model Recommendations
- PLC: Siemens S7-1200 series (e.g., CPU 1214C DC/DC/DC)
- Reason: Supports Modbus-RTU communication (compatible with the inverter), has sufficient I/O points (digital and analog), and is cost-effective.
- Configuration: Includes analog input/output modules (for collecting tension signals and outputting speed reference signals).
- HMI: Siemens KTP700 Basic (7-inch)
- Reason: Compatible with S7-1200, supports Modbus communication, user-friendly interface, suitable for industrial environments.
6.3 PLC and Inverter Communication
- Communication Method: Uses Modbus-RTU protocol (refer to Chapter 6 of the manual).
- Settings:
- Main winding inverter communication address (F7-00) set to 1, baud rate (F7-01) set to 19200bps, data format (F7-02) set to 8-E-1.
- Traverse inverter communication address (F7-00) set to 2, with the same baud rate and data format.
- PLC Program:
- Reads the main winding inverter’s speed (register U0-00).
- Calculates the traverse inverter’s target frequency and writes to register 0x01.
- Monitors fault status (registers U0-51 to U0-71); if a fault occurs, the system stops.
6.4 HMI Interface Design
- Main Interface: Displays main winding motor speed, traverse motor speed, material tension, and operating status.
- Parameter Settings: Sets reel diameter, material thickness, lead screw pitch, maximum speed, etc.
- Control Buttons: Start, stop, emergency stop, and speed adjustment (via slider).
7. Control Schematic (Text Description)
PLC (S7-1200)
|-------> RS485 Communication ------> Main Winding Inverter (Address 1)
|-------> RS485 Communication ------> Traverse Inverter (Address 2)
|
|-------> Analog Output -----> Main Winding Inverter AI1 (Speed Reference)
|-------> Analog Output -----> Traverse Inverter AI1 (Speed Reference)
|
|-------> Digital Input -----> Left Limit Switch
|-------> Digital Input -----> Right Limit Switch
|
|-------> Analog Input -----> Tension Sensor
HMI (KTP700)
|-------> Communicates with PLC for Display and Control8. Implementation Steps
- Installation: Follow Chapter 3 of the manual to install the inverter and motors, ensuring proper ventilation and secure wiring.
- Wiring: Connect the power, motors, and control terminals as per the wiring diagrams above.
- Parameter Settings: Set the inverter parameters as described in Section 4, and test motor operation.
- PLC Programming: Write the speed synchronization and reciprocating motion control logic, and test communication functions.
- HMI Configuration: Design the interface and test operational functions.
- Commissioning: Start the winding machine, adjust speed and tension parameters, and ensure even traversing.
9. Precautions
- Safety: Adhere to the safety precautions in Chapter 1 of the manual, ensuring reliable grounding and avoiding misoperation.
- Motor Parameter Tuning: If using vector control, perform motor parameter auto-tuning (refer to Chapter 4 of the manual).
- Fault Diagnosis: If overcurrent or overvoltage faults occur, refer to Chapter 7 of the manual for troubleshooting.
Through the above solution, the 900 Series Inverter can be effectively applied to the winding machine’s traverse system, achieving speed synchronization, reciprocating motion, and tension control. For more detailed PLC programming or HMI interface design, please feel free to contact us.
This translation maintains the technical accuracy and structure of the original article, with key points emphasized in bold as requested. Let me know if further adjustments are needed!
