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案例详细
标题FC300应用在电镀线收卷设备
技术领域
行业石油天然气
简介
内容

概述:
    某一个客户为钢链线设备生产厂商，电镀线收卷机构为其生产线中的重要设备，主要有三个部分组成:
1. 牵引机构:将镀锌线从电镀设备处牵引过来
2. 排线机构:将镀锌线均匀的分布在收线滚筒上
3. 收线机构:将镀锌线收卷到滚筒上
牵引机构及排线机构是由西门子MM420变频器驱动,收线机构由西门子MM440变频器驱动，由于西门子此系列变频器质量不稳定且经常损坏。因此，我们选用丹佛斯FC300变频器来进行替代，丹佛斯FC300系列变频器具有运行稳定，控制精度高、功能全面等特色，完全能满足客户的生产需求。


在项目实施过程中的调试参数如下：
一，系统参数:
线速度:40m/min
收卷转矩:0—7Nm
牵引电机:2.2KW,380V,50Hz,5.6A,1400RPM
收线电机:1.5KW,380V,50Hz,3.6A,1395RPM
排线电机:0.18KW,380V,50Hz,0.49A,1425RPM


二，FC300参数设置
    牵引变频器:FC302P2K2，采用开环速度控制,将频率信号通过脉冲信号传递给收线变频器，参数如下：
参数号             参数名称                       出厂值（代码）                                   设定值（代码）
1-00                配置模式                        开环速度控制（0）                           开环速度控制（0）
1-20                电机功率                            3.0KW                                                       2.2KW
1-22                电机电压                             400V                                                            380V
1-24                电机电流                             7.0A                                                              5.6A
1-25                电机转速                         1420RPM                                                   1400RPM
1-91                电机外部风扇                        NO                                                              YES
3-03                最大参考值                      1500RPM                                                   2070RPM
3-41                加速时间                             3.0s                                                              10.0s
3-42                减速时间                             3.0s                                                               3.0s
4-13                最大速度限制                    3600RPM                                                  2070RPM
4-14                最大频率限制                   120.0Hz                                                        69.0Hz
4-19                最大输出频率                    132.0Hz                                                          70Hz
5-01                端子27模式                           输入                                                              输出
5-30                端子27功能                          无功能                                                       脉冲输出
5-40                Relay 1功能                         无功能                                                       故障报警
5-60                27端脉冲输出变量              无功能                                                       输出频率
6-14                53号端子参考低                  0RPM                                                          0RPM
6-15                53号端子参考高                 1500RPM                                                 2070RPM
6-16                53号端子滤波时间                 0.001                                                          0.3
6-50                42号端输出功能                    无功能                                                       输出频率
6-52                42号端输出最大比例            100%                                                          70%

    收线变频器:FC302P1K5，采用开环速度控制,配合转矩限制功能使用, 并且将频率信号通过模拟量电压信号传递给排线变频器。变频器参数如下：
参数号                  参数名称                           出厂值（代码）                       设定值（代码）
1-00                      配置模式                            开环速度控制（0）                  开环速度控制（0）
1-01                     电动控制原理                     电压矢量控制                             无传感器磁通矢量
1-20                     电机功率                              1.5KW                                             1.5KW
1-22                     电机电压                               400V                                                380V
1-24                      电机电流                              3.8A                                                  3.6A
1-25                     电机转速                               1420RPM                                    1395RPM
1-91                     电机外部风扇                         NO                                                   YES
3-03                     最大参考值                             1500RPM                                    3090RPM
3-15                     参考值来源1                           模拟量输入端53                           端子33
3-41                     加速时间                                  3.0s                                                  2.0s
3-42                     减速时间                                  3.0s                                                  3.0s
4-13                     最大速度限制                          3600RPM                                    3090RPM
4-14                     最大频率限制                          120.0Hz                                         103.0Hz
4-19                     最大输出频率                          132.0Hz                                          105Hz
4-20                     转矩限制来源                          无功能                                        模拟量输入端53
5-15                     端子33功能                              无功能                                              脉冲输入
5-40                     Relay 1功能                             无功能                                            故障报警
5-55                     端子33低频                              100Hz                                                0Hz
5-56                     端子33高频                               100Hz                                              3500Hz
5-58                     33号端子参考高                      1500RPM                                       3090RPM
6-10                     端子53低电压                             0.07V                                                  2V
6-11                     端子53高电压                             10V                                                    10V
6-16                     53号端子滤波时间                       0.001                                                0.3
6-50                     42号端输出功能                        无功能                                               输出频率

    排线变频器:FC301PK75，采用开环速度控制,配合正反转功能使用.
参数号                                        参数名称                            出厂值（代码）                 设定值（代码）
1-00                                            配置模式                            开环速度控制（0）        开环速度控制（0）
1-20                                            电机功率                            0.75KW                                  0.18KW
1-22                                            电机电压                              400V                                      380V
1-24                                            电机电流                              2.0A                                       0.49A
1-25                                            电机转速                             1420RPM                            1425RPM
1-91                                            电机外部风扇                        NO                                            YES
3-02                                            最小参考值                           0RPM                                  1050RPM
3-03                                            最大参考值                         1500RPM                              4590RPM
3-41                                            加速时间                                  3.0s                                         1.0s
3-42                                             减速时间                                  3.0s                                         1.0s
4-10                                             电机转向                            仅顺时针方向                                双向
4-11                                             最小速度限制                      0RPM                                     1050RPM
4-12                                             最小频率限制                         0Hz                                            35Hz
4-13                                             最大速度限制                       3600RPM                              4590RPM
4-14                                             最大频率限制                         120.0Hz                                  153.0Hz
4-19                                              最大输出频率                         132.0Hz                                160Hz
5-40                                                Relay 1功能                          无功能                                    故障报警

注:
1. 由于电镀线在收卷过程中要保证一定的张力,牵引电机会被收线电机拖着走,所以牵引电机工作在发电机模式下,牵引变频器没有制动单元会出现过电压的报警,我们采用了直流共享解决这个问题。
2. 由于电镀线对张力精度的要求不高，所以收线变频器采用开环速度控制+转矩限制功能完全可以满足客户的工艺要求。