MD380-307# Special drive for wire drawing machine

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Contents

Part 1 Brief introduction of wire drawing machine

Part 2 Solutions for wire drawing machine

Part 3 Commissioning guidance

Technological process of wire
Non-ferrous metal smelting

Continue Casting Direct Rolling

Drawing and annealing Tinning, lacquering

Twisting (High speed)

Single core wire extrusion

Extrusion
Back twisting and pair twisting

Single twisting (Cantilever

Data wire
/ Suspension frame type)

Ecderon extrusion

Cutting, coiling Power wire

Technological process of cable
Non-ferrous metal smelting

Continue Casting Direct Rolling

Drawing and annealing Twisting

Extrusion

Cable-formed twisting

Inner protective layer

Armouring

Outer protective covering

 Technological process of wire/cable---Conductor processing

Non-ferrous metal smelting Drawing: Using wire drawing machine.

Continue Casting Direct Rolling
Drawing and annealing
In the normal temperature, the wire goes through a number of
mold holes, so that the cross section is reduced, the length is
increased, the intensity is improved.
Wire drawing machine is divided into large,medium,small and
micro drawing machine.

：
Drawing process：

Wire let off Wire drawing Wheeled Automatic

Annealing Pull wheel
rack machine traction winding
Technological process of wire/cable---Conductor processing
Wire drawing machine

Drawing part Winding

The wire goes through the hole of mold

Mold
Technological process of wire/cable---Conductor processing
Wire Drawing machine:

The types of mold and its applications:

Hard alloy mold (also called tungsten carbide mold)
---for mass production of various specifications, large wire drawing machine.
Polycrystalline mold
---used for drawing of small and medium size wire
Diamond mold
--- used for production of thin wire
Steel mold
--- for small production of large cross-section type wire and tight twisted wire.

Lubrication:
In the wire drawing process, the lubricant must be injected between the wire and the
mold for lubricating, cooling, and cleaning.
In general, the emulsion lubricant for copper wire drawing, the semi liquid lubricant for
aluminium wire drawing.
Technological process of wire/cable---Conductor processing
Wire Drawing machine:
Classification:
A Single mold wire drawing machine
B Multi molds wire drawing machine： ：
a). Non continuous type (saving): i. Single wire storage wheel; ii. Double wire storage wheels
b). Continuous type: i . Slide type ii . Non slide type

Outlet Maximum
Power of main Outlet Diameter of
Machine wire inlet wire Number
motor speed drum wheel
grade diameter diameter of mold
(kW) (m / s) (mm)
(mm) (mm)
Large wire
drawing 4-1.2 8 13 185 6.6-16.5 400
machine
Medium 1.2-0.4 3 17 55 15-25 280

Small 0.4-0.12 1.6 17 22 15-25 200

Fine 0.15-0.05 0.6 17 4 15-25 150

Micro 0.05-0.02 0.12 20 1.1 15-25 69

Technological process of wire/cable---Conductor processing
Non-slide continuous type
◆ Multi molds, no relative sliding between the wire and the drum wheel;
◆ The line speed of wire is the same as that of drawing wheel;
◆ The volume of wire per second is equal between each mold, continuous drawing process
(such as straight wire drawing machine), no wear in the surface of wire;
◆ Speed control system is complicated, the cost is relatively high, mainly used for drawing
aluminum and aluminum alloy wire (or steel wire).

A1、A2…Ak : Cross-sectional area of outlet wire after each mold;

B1、B2…Bk : Line speed of wire after each drawing wheel;
V1、V2…Vk: Line speed of each drawing wheel;
u1、u2…uk: Lengthening coefficient of each mold;

Due to there is no sliding, we know: Bn= vn

Due to equal volume of wire per second, we know: An-1*Bn-1= An*Bn
So An-1/An = Bn/Bn-1 = vn/vn-1
Technological process of wire/cable---Conductor processing

Non-slide continuous large wire drawing machine:

Every drawing wheel is drove by 1 motor, the end motor is responsible for wire winding.
Technological process of wire/cable---Conductor processing
Slide type continuous wire drawing machine
◆ The line speed of drawing drum wheel is more than wire ’ s, which results in friction to
draw the wire through the mold.
◆ According to the shape, the wire drawing wheel can be divided into two kinds: tower
type and cylinder type.
◆ There is wear in the surface of wire, suitable for medium strength of copper wire
drawing, not suitable for aluminum wire.
Tower type：
The behind drawing speed is more than the front’s, if several drawing wheels are installed on the
same transmission shaft, the diameter of behind drawing wheels should be larger than that of the
front wheels, so it forms the tower structure.（such as double inverter wire drawing machine）

Cylinder type: Adopt equal diameter drawing wheels, each wheel is driven by individual shaft,
however it brings the disadvantage of big volume.
Technological process of wire/cable---Conductor processing

Slide continuous large wire drawing machine:

All drawing wheels are drove by 1 motor, the end motor is responsible for wire winding.
Technological process of wire/cable---Conductor processing

Medium wire drawing machine:

slide continuous drawing, 1 motor for drawing,
1 motor for winding.
Technological process of wire/cable---Conductor processing

Small wire drawing machine:

slide continuous drawing, 1 motor for drawing,
1 motor for winding. Adopt inverter or servo for
winding displacement.
Technological process of wire/cable---Conductor processing

Micro wire drawing machine:

slide continuous drawing, 1 motor for drawing, 1 motor for winding. Adopt inverter or
servo for winding displacement.
Contents

Part 1 Brief introduction of wire drawing machine

Part 2 Solutions for wire drawing machine

Part 3 Commissioning guidance

Solutions for wire drawing machine
Technological features:
◆ No curling diameter calculation (curling diameter ratio within 1:2);
◆ High torque at low speed ( Jog running, convenient for wire passing through the mold);
◆ “ Main frequency + PID ” or “Independent PID” for tension control ( “Independent PID” is
only suitable for winding / unwinding.
◆ High precision of speed control;
◆ High performance of PID control;
◆ Good linearity of acceleration and deceleration;
◆ Fast dynamic response

Curling diameter ratio = Min. Curling diameter :Max. Curling diameter

 Solutions for wire drawing machine

Active wire Wire

unwinding Main drawing
winding

IM

IM IM

MD380-307#

MD380-307# MD380-307#

PLC HMI
Solutions for wire drawing machine
Double inverter wire drawing machine
Solutions for wire drawing machine
Advantages:
1. Multi application macro parameters, easy to use.
FP-01=5 Wire winding application 1( Independent PID );
FP-01=6 Main drawing 1 ( Fault reset automatically);
FP-01=7 Wire winding application 2 ( “Main frequency + PID” );
FP-01=8 Main drawing 2
FP-01=9 Drawing application for straight wire drawing machine;
FP-01=10 Active wire unwinding;

2. High performance of PID algorithm

◆ Only 1 group of PID parameters is competent to respond to curling diameter change from empty
reel to full reel, no curling diameter calculation;
◆ For complex tension control, multi PID parameters are available;
◆ High detection capability of feedback value variation, the allowed minimum variation range is 2V.
This can help to save the amplified gear of swing rod detection mechanism;
◆ Adapt to different diameter/ different material wire;

3. Practical assistant control functions

◆ Wire break off detection ( Detection signal input DI; PID feedback loss detection) ;
◆ Brake control ( DO/ Relay output brake signal for the control of external brake mechanism);

4. Rich communication interfaces

Support Modbus, Profibus-DP, CANlink, CANopen.
Contents

Part 1 Brief introduction of wire drawing machine

Part 2 Solutions for wire drawing machine

Part 3 Commissioning guidance

Commissioning guidance
：Auto-tuning
Step 1：
Restore factory settings: FP-01=1;
Input motor parameters: F1-00 ~ F1-05;
F0-02=0, F1-37= 2 or 3 ( 2 for off load; 3 for with load)

：Select proper macro parameters

Step 2：
FP-01=5 Wire winding application 1( Independent PID );
FP-01=6 Main drawing 1 ( Fault reset automatically);
FP-01=7 Wire winding application 2 ( “Main frequency + PID” );
FP-01=8 Main drawing 2
FP-01=9 Drawing application for straight wire drawing machine;
FP-01=10 Active wire unwinding;

：Verify the feedback extreme value of swing rod

Step 3：
Monitor U0-09 (AI1)/ U0-10 (AI2) to confirm the minimum and maximum feedback values
corresponding with the lowest and highest position of swing rod, then fill both values in F4-13 and
F4-15 (when select AI1 as feedback) / F4-18 and F4-20 (when select AI2 as feedback).
Commissioning guidance
1. Default value of parameters for wire winding
Function code Description FP-01=5 FP-01=7
F0-02 Command source selection 1 1
F0-03 Main frequency source X selection 8 (PID) 3 (AI2)
F0-04 Auxiliary frequency source Y selection 0 8
F0-07 Frequency source selection 0 1
F0-10 Maximum frequency 80.00 Hz 80.00 Hz
F0-12 Frequency upper limit 80.00 Hz 80.00 Hz
F0-17 Acceleration time 1 1.0 s 1.0 s
F0-18 Deceleration time 1 1.0 s 1.0 s
F2-00 Speed loop proportional gain 1 50 50
F2-01 Speed loop integral time 1 1.0 1.0
F2-03 Speed loop proportional gain 2 60 60
F2-04 Speed loop integral time 2 3.0 3.0
F4-00 DI1 function selection 1 1
F4-01 DI2 function selection 0 4
F4-02 DI3 function selection 0 9
F4-03 DI4 function selection 0 12
F4-04 DI5 function selection 9 (fault reset) 13
Commissioning guidance
1. Default value of parameters for wire winding

Function code Description FP-01=5 FP-01=7

F5-02 Relay function (T/A-T/B-T/C) 3 (FDT ) 2 (fault output)
F6-10 Stop mode 1 1
F9-09 Fault auto reset times 30 0
F9-10 DO action during fault auto reset 1 0
F9-11 Time interval of fault auto reset 6.0 s 6.0 s
FA-05 Proportional gain Kp1 10.0 10.0
FA-06 Integral time Ti1 0.8 0.8
FA-07 Differential time Td1 0.350 0.350
FA-11 PID setting change time 5.0 s 5.0 s
FA-26 Detection value of PID feedback loss 10.0% 0
FA-27 Detection time of PID feedback loss 0.5 s 0
Commissioning guidance
2. Default value of parameters for Main drawing
Function code Description FP-01=6 FP-01=8
F0-02 Command source selection 1 1
F0-03 Main frequency source X selection 8 (PID) 3 (AI2)
F0-04 Auxiliary frequency source Y selection 0 0
F0-07 Frequency source selection 0 0
F0-10 Maximum frequency 75.00 Hz 75.00 Hz
F0-12 Frequency upper limit 75.00 Hz 75.00 Hz
F0-17 Acceleration time 1 80.0 s 80.0 s
F0-18 Deceleration time 1 80.0 s 80.0 s
F2-00 Speed loop proportional gain 1 30 30
F2-01 Speed loop integral time 1 1.0 1.0
F2-03 Speed loop proportional gain 2 30 30
F2-04 Speed loop integral time 2 1.0 1.0
F4-00 DI1 function selection 1 1
F4-01 DI2 function selection 4 4
F4-02 DI3 function selection 8 9
F4-03 DI4 function selection 51( wire break 12
off detection)
F4-04 DI5 function selection 9 (fault reset) 13
Commissioning guidance
2. Default value of parameters for Main drawing

Function code Description FP-01=5 FP-01=7

F5-02 Relay function (T/A-T/B-T/C) 42 (brake 2 (fault output)
output)
F6-10 Stop mode 0 0
F8-00 JOG running frequency 4.00 Hz 2.00 Hz
F8-01 JOG acceleration time 5.0 s 20.0 s
F8-02 JOG deceleration time 5.0 s 20.0 s
F9-09 Fault auto reset times 30 0
F9-10 DO action during fault auto reset 1 0
F9-11 Time interval of fault auto reset 6.0 s 6.0 s
Commissioning guidance
3. Default value of parameters for straight drawing machine
Function code Description FP-01=9
F0-02 Command source selection 1
F0-03 Main frequency source X selection 3 (AI2)
F0-04 Auxiliary frequency source Y selection 8 (PID)
F0-05 Range of auxiliary frequency Y for X and Y operation 1
F0-06 Range of auxiliary frequency Y for X and Y operation 70%
F0-07 Frequency source selection 1
F0-10 Maximum frequency 95.00 Hz
F0-12 Frequency upper limit 95.00 Hz
F0-17 Acceleration time 1 1.0 s
F0-18 Deceleration time 1 1.0 s
F2-00 Speed loop proportional gain 1 30
F2-01 Speed loop integral time 1 1.0
F2-03 Speed loop proportional gain 2 30
F2-04 Speed loop integral time 2 1.0
Commissioning guidance
3. Default value of parameters for straight drawing machine
Function code Description FP-01=9
F4-00 DI1 function selection 1
F4-01 DI2 function selection 22 (PID pause)
F4-02 DI3 function selection 9
F5-02 Relay function (T/A-T/B-T/C) 2 (Fault output)
F6-10 Stop mode 1
FA-05 Proportional gain Kp1 4.5
FA-06 Integral time Ti1 2.0
FA-07 Differential time Td1 0
FA-11 PID setting change time 0
Commissioning guidance
4. Default value of parameters for active wire unwinding
Function code Description FP-01=9
F0-02 Command source selection 1
F0-03 Main frequency source X selection 8 (PID)
F0-10 Maximum frequency 50.00 Hz
F0-12 Frequency upper limit 50.00 Hz
F0-17 Acceleration time 1 1.0 s
F0-18 Deceleration time 1 1.0 s
F2-00 Speed loop proportional gain 1 50
F2-01 Speed loop integral time 1 1.0
F2-03 Speed loop proportional gain 2 50
F2-04 Speed loop integral time 2 1.0
F4-00 DI1 function selection 1
F4-01 DI2 function selection 8 (Free stop)
F4-02 DI3 function selection 9 (Fault reset)
FA-05 Proportional gain Kp1 15
FA-06 Integral time Ti1 1.3
FA-07 Differential time Td1 0
FA-08 Cut-off frequency of PID reverse rotation 50 Hz
FA-11 PID setting change time 0
Commissioning guidance
Assistant control function--- Wire break off detection Err24 fault
Method 1: Meet with the following conditions:
DI (51# wire break off signal function) is effective
Running time exceed A9-07 ( wire break off detection delay time)

Method 2: Use PID feedback loss detection function:

Commissioning guidance
Assistant control function--- Brake control
Method 1: Use FDT detection function:
Commissioning guidance
Assistant control function--- Brake control
Method 2: Use special brake control logic:
A9-05 : Brake action frequency ; A9-06: Brake effective delay time
During the period of decelerate to stop, if the running frequency less than A9-05, the brake
output signal (DO/ Relay) will ON. After the motor stop absolutely, delay a certain time (A9-06),
then the brake output signal will OFF.
Commissioning guidance
Position detection potentiometer of swing rod
If without amplified gear, the variable range of
feedback value is 2V only;
After using amplified gear, the range can reach 6~7V.

MD380-307# can save amplified gear.

For small variable range such as 2V, just need to
set the following parameters:
FA-13 =20% (PID deviation gain);
FA-05=20 ( Proportional gain);
Commissioning guidance
Straight wire drawing machine or annealing process
There is no curling diameter variation in drawing process or annealing process.

A9-11 Main frequency gain: Default value 1.00, adjusting it properly can make the line
speed better synchronous.

１st draft ２nd draft N draft

winding
Mold displacement.

Winding

M M M
Swing rod Swing rod

Drawing
process
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