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Application Scheme of Parker 590+ DC Drive in Blow Molding Machines

I. Introduction

Blow molding machines are critical equipment for producing hollow plastic products (such as PE bottles and containers). The process involves several steps, including extrusion, clamping, blow molding, cooling, and mold opening. The Parker 590+ DC drive, with its precise speed and torque control capabilities, is particularly well-suited for controlling DC motors in blow molding machines. This document elaborates on how to apply the 590+ drive to a PE material blow molding machine, covering motor functions, wiring schemes, parameter settings, control system integration, and textual descriptions of electrical wiring diagrams and control schematics.

II. Analysis of Motor Functions in Blow Molding Machines

The process flow of a blow molding machine (especially for PE material extrusion blow molding) includes:

  • Extrusion: Plastic pellets are melted through the extruder screw to form a tubular parison.
  • Clamping: The mold closes, clamping the parison.
  • Blow Molding: Air is injected into the parison to expand and form the shape.
  • Cooling: The molded product is cooled.
  • Mold Opening: The mold opens, and the finished product is removed.

Motor Functions
Based on the blow molding process, the following motors are suitable for use with the 590+ DC drive:

  • Extruder Motor:
    • Function: Drives the screw to control plastic melting and extrusion speed.
    • Requirements: Precise speed control, smooth acceleration/deceleration, and overload protection.
    • Reason: PE materials require a stable extrusion speed to ensure uniform parison formation. Baumüller emphasizes the need for high torque and precise speed control in extruders.
  • Clamping Unit Motor:
    • Function: Controls the opening and closing of the mold.
    • Requirements: Rapid response and precise speed or position control.
    • Reason: Quick and accurate mold movements can improve production efficiency. Plastics Technology mentions the need for precise control in clamping systems.

Motor Specifications (Based on User Input)

  • Rated Voltage: 440V
  • Rated Current: 25.1A
  • Power: 15kW
  • Speed: 1500 rpm
  • Field Excitation: Field current not provided; assumed to use voltage control mode.
  • Assumption: The extruder motor uses the above specifications. The clamping unit motor specifications may differ (e.g., 10A, assumed value) and should be adjusted according to the actual nameplate.

III. Application Design of the 590+ DC Drive

  1. Application Positions and Functions
    • Extruder Motor
      • Control Mode: Speed Setpoint mode.
      • Function: Precisely control the screw speed to ensure uniform melting of PE materials; maintain stable extrusion through PID control; use Ramp function for smooth start-up and shutdown.
      • Implementation: The drive receives a 0-10V speed reference signal from the PLC and feeds back the actual speed through an encoder or DC generator.
    • Clamping Unit Motor
      • Control Mode: Speed Setpoint mode (or Position Control mode if supported).
      • Function: Control the rapid closing and opening of the mold; ensure precise movements and reduce mechanical shock.
      • Implementation: The drive receives open/close commands from the PLC and may use limit switches for position control.
  2. Wiring Scheme
    • Motor Connections
      • Extruder Motor: Connect the armature to the drive’s A1 (positive)/A2 (negative) terminals; if the field is internally powered, no connection is needed; if external, connect to FL1/FL2 terminals (refer to Eurotherm Manual).
      • Clamping Unit Motor: Same as above, to be confirmed based on actual motor specifications.
    • Control Signal Connections
      • Speed Reference: Connect the PLC analog output (0-10V) to the A4 terminal (ANIN3), ensuring signal shielding to reduce noise.
      • Start/Stop: Connect the PLC digital output to the C3 terminal (DIGN2 for start); connect the PLC digital output to the C4 terminal (DIGN3 for stop, or use a single signal).
      • Feedback: Connect the encoder to the drive’s encoder input terminals; connect the DC generator to the TB terminal.
      • Communication: Connect the P3 port to the PLC communication interface (e.g., RS-485) for data exchange.
    • Power Connections
      • Main Power: Connect the three-phase AC power (380V or matching voltage) to the L1/L2/L3 terminals.
      • Control Power: Connect 24V DC to the C9 (+24V)/C10 (0V) terminals.
    • Wiring Precautions
      • Use shielded cables to reduce electromagnetic interference.
      • Ensure proper grounding to comply with safety standards.
      • Refer to the wiring diagram in Appendix L of the manual.
  3. Parameter Settings
    • Extruder MotorParameter NameLabelSetting ValueRangeDefault ValueNotesARMATURE V CAL.201.03530.9800 to 1.10001.0000Voltage switch set to 425VCUR. LIMIT/SCALER15100.00%0.00 to 200.00%100.00%Corresponding to 25.1AMAIN CURR. LIMIT421100.00%0.00 to 200.00%200.00%Adjustable as neededFIELD CONTROL MODE209VOLTAGEVOLTAGE/CURRENTVOLTAGEVoltage control modeRATIO OUT/IN21090.00%0.00 to 100.00%90.00%Initial field voltage ratioSPEED FBK SELECT10ENCODERMultiple options-Assume using encoderMODE1Speed SetpointMultiple modes-Speed control modeRAMP RATE (Accel)25.0 seconds0.1 to 600.0 seconds-Smooth accelerationRAMP RATE (Decel)35.0 seconds0.1 to 600.0 seconds-Smooth deceleration
    • Clamping Unit Motor
      • Assume current is 10A; other parameters are similar.
    • Setting Steps
      • Enter the configuration mode via MMI (CONFIGURE ENABLE = ENABLED).
      • Set the above parameters, referring to the manual’s menu system.
      • Save the parameters (CONFIGURE ENABLE = DISABLED).
  4. Control System Integration
    • PLC Selection
      • Recommended: Siemens S7-1200 (compact, suitable for small and medium-sized blow molding machines) or S7-300 (suitable for large equipment).
      • Functions: Control the process flow (extrusion, clamping, blow molding, mold opening); send analog signals (speed reference) and digital signals (start/stop); receive feedback from the drive (speed, current, faults).
      • Modules: Analog output module (e.g., EM 231, 0-10V); digital output module (e.g., EM 222); communication module (e.g., RS-485).
    • HMI Selection
      • Recommended: Siemens KTP700 Basic or Allen-Bradley PanelView Plus.
      • Functions: Display extrusion speed, motor current, fault status; provide start/stop buttons, speed setting interface; alarm management.
      • Interface Example: The home page displays running status, speed, and current; the setting page adjusts extrusion speed and clamping speed; the alarm page displays drive fault codes.
    • Industrial PC (Optional)
      • Recommended: Siemens Simatic IPC477E or Beckhoff CX5130.
      • Functions: Recipe management (store parameters for different PE products); data logging (production data, fault logs).
      • Applicable Scenarios: Large production lines or when advanced automation functions are required.
    • Control Logic
      • PLC Program: The main cycle executes the process steps in sequence (extrusion → clamping → blow molding → cooling → mold opening); set the speed reference (e.g., 50%) when the extruder starts and activate the C3 terminal; stop by closing the C3 terminal and setting the speed to 0; send a close command (speed 100%) to the clamping unit before blow molding and an open command (speed -100% or reverse) after blow molding.
      • Example Logic (Textual Description)
        • Press the “Start” button: Output the speed reference (Q0.0, 0-10V) to A4; activate C3 (Q0.1, start).
        • Clamping phase: Output the clamping speed (Q0.2, 0-10V) to the clamping drive’s A4; activate the clamping C3 (Q0.3, start).
  5. Electrical Wiring Diagram and Control Schematic
    • Extruder Wiring Diagram (Textual Description)
      • [Three-phase power 380V] –> [L1/L2/L3] –> [590+ input terminals]
      • [24V DC power] –> [C9(+24V)/C10(0V)] –> [590+ control power]
      • [Extruder motor armature] –> [A1/A2] –> [590+ output terminals]
      • [Extruder motor field] –> [FL1/FL2] –> [590+ field terminals] (if external)
      • [PLC analog output 0-10V] –> [A4(ANIN3)] –> [590+ speed reference]
      • [PLC digital output] –> [C3(DIGN2)] –> [590+ start]
      • [PLC digital output] –> [C4(DIGN3)] –> [590+ stop]
      • [Encoder] –> [Encoder input] –> [590+ feedback]
    • Clamping Unit Wiring Diagram (Textual Description)
      • [Three-phase power 380V] –> [L1/L2/L3] –> [590+ input terminals]
      • [24V DC power] –> [C9(+24V)/C10(0V)] –> [590+ control power]
      • [Clamping motor armature] –> [A1/A2] –> [590+ output terminals]
      • [Clamping motor field] –> [FL1/FL2] –> [590+ field terminals] (if external)
      • [PLC analog output 0-10V] –> [A4(ANIN3)] –> [590+ speed reference]
      • [PLC digital output] –> [C3(DIGN2)] –> [590+ start]
      • [PLC digital output] –> [C4(DIGN3)] –> [590+ stop]
      • [Limit switch] –> [Digital input] –> [590+ position feedback]
    • Control Schematic (Textual Description)
      • [Operator] –> [HMI KTP700]
      • [HMI] –> [PLC S7-1200]
      • [PLC] –> [Analog output Q0.0] –> [Extruder 590+ A4]
      • [PLC] –> [Digital output Q0.1] –> [Extruder 590+ C3]
      • [PLC] –> [Analog output Q0.2] –> [Clamping 590+ A4]
      • [PLC] –> [Digital output Q0.3] –> [Clamping 590+ C3]
      • [Extruder 590+] –> [Extruder motor] –> [Screw]
      • [Clamping 590+] –> [Clamping motor] –> [Mold]
      • [PLC] –> [Other control] –> [Blow molding valve, cooling system]

IV. Implementation Steps

  1. Wiring
    • Confirm the power supply voltage (380V or matching).
    • Connect the motor armature (A1/A2) and field (FL1/FL2, if needed).
    • Connect the control power (C9/C10).
    • Connect the PLC analog output to A4 and digital output to C3/C4.
    • Connect the feedback device (encoder or DC generator).
    • Connect the P3 port to the PLC communication interface.
  2. Parameter Setting
    • Enter the MMI and set CONFIGURE ENABLE = ENABLED.
    • Set parameters such as armature voltage, current limit, field control mode, etc.
    • Configure speed feedback and control mode.
    • Save the parameters and set CONFIGURE ENABLE = DISABLED.
  3. PLC and HMI Configuration
    • Write the process control program in the PLC.
    • Configure the HMI interface, adding status displays and control buttons.
    • Test the communication (PLC with the drive).
  4. Testing and Debugging
    • Power on and check the drive status (no alarms).
    • Start the extruder via the HMI and verify speed control.
    • Test the clamping unit’s opening and closing to ensure accurate movements.
    • Adjust parameters (e.g., Ramp time, PID gain) to optimize performance.

V. Precautions

  • Safety: Ensure power is disconnected before wiring and follow electrical safety standards.
  • Debugging: Test gradually to avoid motor overload or mechanical damage.
  • PE Material Characteristics: Ensure that the extrusion speed is coordinated with temperature control (refer to ScienceDirect).
  • Manual Reference: Detailed wiring and parameter settings should be consulted in the Eurotherm Manual.

VI. Conclusion

By applying the Parker 590+ DC drive to the extruder and clamping unit of a blow molding machine, precise motor control can be achieved, improving the production efficiency and quality of PE products. The wiring scheme ensures reliable signal transmission, parameter settings match motor requirements, and PLC and HMI integration enables automated control. This scheme is a general design and may require微调 (fine-tuning) based on specific equipment and processes in practical applications.

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