Category: electromechanical technology

1. Overview of the Process

The automatic chili pepper cooking production line consists of six main steps:

1. Raw Material Transport and Cleaning
   • Conveyor/Screw Lifter: Transports fresh chili peppers to the cleaning section.
   • Bubble Washing Machine: Uses water flow and bubbles to remove dirt, pesticides, and residues from the peppers.
2. Preprocessing: Sorting and Cutting
   • Sorting and Grading: Manual or vibrating conveyors automatically sort out defective peppers.
   • Cutting Equipment: Cuts peppers into segments or small pieces, ensuring uniform size for cooking and grinding.
3. Cooking for Flavor Extraction
   • Continuous Cooking Machine: Uses steam or electric heating to cook the peppers at 70°C to 90°C for 30 to 90 minutes, extracting flavor and heat while softening the peppers.
4. De-watering and Separation
   • Vibration Dewatering Machine: Removes excess water from the cooked peppers, making them easier to grind.
5. Flavoring and Grinding
   • Chili Paste Machine: Adds seasonings such as salt, sugar, garlic, and oil, then grinds the mixture into chili paste.
6. Packaging and Sterilization
   • Filling Machine → Sterilization Cooker: Quickly fills containers, seals, and sterilizes the chili paste to ensure freshness and shelf-life.
7. Storage
   • The finished products are stored in a cold storage or shipped for distribution.

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2. Equipment and Process Design Logic

The equipment configuration and sequence design are tailored to meet process requirements, enhancing automation and efficiency.

Stage	Key Equipment	Function
Transport & Cleaning	Screw Lifter → Bubble Washing Machine	Ensures uniform raw material size and cleanliness
Cutting	Sorting Table → Cutting Machine	Ensures uniform size for efficient cooking and grinding
Cooking → De-watering	Continuous Cooking Machine → Vibration Dewatering Machine	Evenly softens and separates water for easier processing
Flavoring & Grinding	Chili Paste Machine	Uniform mixing and grinding for consistent texture
Packaging & Sterilization	Filling Machine → Sterilization Cooker	Quick filling and sterilization to preserve quality

• Conveying and Cleaning: The screw lifter evenly transports peppers to the washing station, where bubbles and spray jets ensure thorough cleaning.
• Cutting: The cutting machine ensures uniform sizes, which is critical for consistent cooking and grinding results.
• Cooking: The peppers are evenly cooked using steam or electric heating, with mechanisms in place to ensure uniform heat distribution.
• De-watering: The vibration dewatering machine removes excess water, reducing processing load for the next stages.
• Flavoring & Grinding: The chili paste machine grinds the chili, creating uniform products with controlled spice levels.
• Packaging: The filling machine ensures consistent product weight, while the sterilization process ensures food safety.

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3. Automation Logic and Control Principles

The core of the automation system includes PLC + HMI + Frequency Inverter + Temperature Control System, working together to ensure seamless operation.

1. PLC (Programmable Logic Controller)

• Receives signals from various sensors (temperature, flow, level, photoelectric, encoder, etc.).
• Executes sequential control: cleaning → cutting → cooking → grinding → packaging.
• Integrates alarm systems and fault-switching logic for automatic downtime in case of issues.

2. HMI (Human-Machine Interface)

• Allows operators to set parameters via a touchscreen: cooking temperature, time, motor speeds, etc.
• Displays real-time operation status, alarms, and performance statistics.

3. Frequency Inverter Control (Longi 900 Series)

• Controls the speed of motors in equipment such as the conveyor, cutting machine, chili paste machine, and filling machine.
• Provides soft start, stepless speed regulation, and overload protection, ensuring longer equipment life.
• Allows precise adjustment of flow rates, coordinated with the PLC for a closed-loop system.

Example Promotion: The Rongji 900 Series Frequency Inverter uses advanced vector control technology, supporting V/F and FOC vector control, with multiple industrial network protocols such as Modbus, Profibus, and Profinet. It offers quick response times, strong anti-interference capabilities, and excellent flexibility, making it an ideal choice for food processing equipment that requires precise flow, torque, and load adjustments. It can save up to 20-30% in energy, reducing operating costs and maintenance needs.

4. Temperature Control System

• Multiple temperature probes monitor cooking conditions, with feedback to the PID controller.
• The PLC uses PID adjustment to control steam valves or electric heating power, maintaining a constant temperature within ±1-2°C.

5. Flow and Level Control

• Water flow for cleaning and spraying is regulated by the frequency-controlled pumps, optimizing water use.
• The sterilization system uses level control sensors to ensure the correct liquid levels are maintained.

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4. Control Workflow and System Principles

4.1 PLC Master Logic Architecture

1. Initial diagnostics → Reset all equipment.
2. Set parameters via HMI.
3. Start the sequence by pressing the “Start” button.
4. Cleaning → Cutting → Cooking → Grinding → Filling → Packaging.
5. Critical sensors (temperature, weight, flow) monitor performance and stop the system if any issue is detected.
6. Data is recorded for traceability.

4.2 Variable Regulation and Protection

• Temperature Deviation: PID control adjusts heating power; deviations beyond ±5°C trigger alarms and stop the system.
• Flow Speed Abnormality: Encoders and inverters monitor the speed; if deviations persist for over 10 seconds, the system halts.
• Filling Weight Deviation: Weight sensors ensure accurate filling; deviations beyond ±2% trigger alarms.

4.3 Equipment Protection

• The frequency inverter provides protection against overload, undervoltage, short circuits, and overheating.
• The PLC monitors emergency stops, door locks, and temperature extremes, halting operations immediately if necessary.
• Faults are automatically reported and logged for further troubleshooting.

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5. Material Selection for Control System

5.1 Frequency Inverter Selection

• Rongji 900 Series Frequency Inverter:
  • Stable performance with high dynamic V/F and FOC control.
  • Compatible with Modbus RTU, Profinet, and EtherCAT, allowing easy integration with PLC systems.
  • Built-in motor protection features, extending system life.
  • Energy-saving up to 20-30%, significantly reducing operational costs.

5.2 Motors and Sensors

• Food-grade, waterproof motors, paired with the frequency inverter for speed control.
• Temperature Sensors: PT100 or thermocouple types for high-temperature resistance.
• Level Sensors: Capacitive or ultrasonic types for high accuracy in sterilization tanks.

5.3 Piping and Materials

• The entire system uses SUS304 or SUS316 stainless steel for food-grade safety, easy cleaning, and corrosion resistance.
• All parts in contact with chili peppers are designed for easy disassembly and cleaning.

5.4 Electrical Control and Distribution

• Control cabinets made from cold-rolled steel or stainless steel, meeting IP protection standards.
• Circuit breakers, grounding protection, and surge protectors are incorporated.
• Remote monitoring capabilities for integration with MES/SCADA systems.

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6. Advantages of Longi 900 Series Frequency Inverter in the System

The Rongji 900 Series Frequency Inverter is perfectly suited for controlling equipment in chili pepper processing lines due to its advanced features:

• Application: Ideal for motors with variable speeds and torque requirements, such as conveyors, grinders, and pumps.
• Performance: Offers rapid response with steady output, capable of handling sudden load changes without destabilizing operations.
• Communications: Features Modbus, Profibus, Profinet, and Ethernet for seamless PLC integration.
• Maintenance: Built-in protection features minimize system downtime, enhancing reliability.
• Energy Efficiency: Energy savings up to 30%, leading to lower operational costs.

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7. Conclusion and Suggested Learning Path

1. Understanding the Process: Familiarize yourself with each step of the production line, from cleaning to packaging, and the risks involved at each stage.
2. Equipment Coordination: Recognize how each piece of equipment contributes to the overall flow, reducing downtime and optimizing efficiency.
3. Automation System: Understand how the PLC, HMI, frequency inverter, and sensors work together to ensure smooth operations.
4. Material Selection: Make sure you choose high-quality components like the Rongji 900 Series Frequency Inverter, which ensures system longevity and reduces operating costs.
5. Learning Path:
   • Study the equipment manuals and PLC programming.
   • Visit production lines for hands-on experience.
   • Attend supplier training for a deeper understanding of the Longi 900 Series Frequency Inverter.
   • Conduct simulations and optimize PID parameters to improve system response.

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1. Product Overview and Working Principle

The RG148 series from ebm-papst utilizes EC (Electronically Commutated) motor technology, integrating a rectifier, inverter, and a brushless DC (BLDC) motor into a compact unit. Instead of using a traditional AC induction motor and external variable frequency drive (VFD), these fans convert AC mains to DC internally and use an IGBT inverter to generate three-phase PWM signals that drive the motor.

Key Advantages

• High Efficiency: No belt or rotor copper loss; system efficiency >90%.
• Brushless & Maintenance-Free: No mechanical commutation—electronic switching replaces brushes.
• Easy Speed Control: A simple 1–6 kHz PWM or 0–10 V analog input allows linear speed regulation.

These fans are ideal for applications requiring wide speed ranges, low maintenance, and energy savings of up to 30% compared to traditional setups.

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2. Connector Definitions and Wiring

The fan features a 5-pin control connector alongside L/N/PE power terminals. The connector is typically an AMP MATE-N-LOK or Molex Mini-Fit Jr. housing, with pin numbers (“1–5”) molded into the plastic shell.

Pin	Wire Color (Original Harness)	Function	Description
1	Blue	GND (Signal Ground)	SELV ground, isolated from chassis
2	Yellow	PWM IN / 0–10 V	1–6 kHz square wave; >20% for startup, >5% for run
3	—	N.C. (Not Connected)	Reserved
4	White	Tach Out	2 pulses/rev, open-collector output
5	Brown	+18 V Output	Max ~20 mA, for pull-up or optocoupler supply

How to identify pins:

1. Visually inspect the connector for molded pin numbers or orientation notch.
2. With power applied, use a multimeter: the only stable ~18 V pair indicates Pin 1 (GND) and Pin 5 (+18 V).
3. Injecting PWM into Pin 2 should spin the fan—this helps verify its identity.

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3. Minimal Wiring for Testing

Power Side: Connect L/N to 230 V AC (or 115 V for low-voltage variants). Add a 6 A slow-blow fuse. PE must be grounded for safety.

Control Side (minimum 3 wires):

• Pin 1 → Connect to your microcontroller or function generator GND
• Pin 2 → Feed a 0–5 V PWM signal through a 1 kΩ resistor
• Pin 4 / Pin 5 → Optional; leave unconnected during basic testing

Startup Procedure

1. With the fan powered off, complete wiring.
2. Power on with PWM = 0%.
3. Output a 30% duty PWM (e.g. 3 kHz); the fan should spin up smoothly.
4. Adjust duty cycle and observe speed changes.
5. Set PWM <3% to stop the fan.

This minimal setup allows safe testing without needing feedback circuits.

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4. Tuning Parameters and Performance Verification

Parameter	Recommended Value	Purpose
PWM Frequency	2–4 kHz	Avoids audible noise
Startup Duty	≥25%	Ensures soft start
Minimum Duty	>5%	Fan stops below this value
RPM Calculation	rpm = freq × 30	Based on Tach signal (2 p/rev)

By measuring the Tach frequency and correlating it with airflow or pressure, you can build a duty-RPM-airflow map for system tuning or PID feedback control.

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5. Common Faults and Troubleshooting

Symptom	Possible Cause	Check / Solution
No rotation	PWM <20%; no GND; internal fuse blown	Oscilloscope on Pin 2; verify Pin 1–5 = +18 V; check fuse
Whining or jittering	PWM freq too low; sharp duty changes	Set to 2–4 kHz; ramp the duty smoothly
No Tach pulse	Missing pull-up or overvoltage	Pull up Pin 4 to +18 V with 10 kΩ or use voltage divider
Overheat shutdown	Poor ventilation; ambient >60°C	Clean airflow path; reduce speed/load
EMI interference	Long unshielded wires	Use shielded twisted pairs; add 100 Ω damping resistors on Pin 2/4

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6. Maintenance and Advanced Configuration

• Routine Check: Every 3 months, clean the impeller and check grounding screws; test insulation yearly.
• Cable Management: For >1 m signal wires, use shielded twisted pairs and ground the shield at one end.
• EEPROM Configuration: Use ebm-papst EC-Control software via Bluetooth or RSB bus to tweak internal parameters (e.g. soft-start ramp, min RPM).
• Harmonic Filtering: For multiple fans on a shared supply, consider adding filters or 12-pulse rectifiers to reduce THDi.

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7. Conclusion

The RG148 EC fan series represents a highly efficient and compact solution for modern ventilation systems. With its integrated inverter and brushless motor, it provides wide-speed-range performance without external VFDs. By mastering the 3-wire minimal control method, understanding PWM tuning, and applying basic troubleshooting, engineers can easily integrate and commission these fans in test setups and production lines. For advanced applications, feedback via Tach signals and EEPROM customization further enhances control accuracy and energy efficiency.

This guide aims to provide a comprehensive, practical overview to help users get the fan up and running safely, optimize its performance, and resolve common issues in real-world scenarios.

1. Overview and Requirements of the Packaging Rope Production Line

The packaging rope production line is widely used for processing polypropylene (PP) and polyethylene (PE) materials. It primarily involves extrusion, stretching, twisting, and winding to produce the required packaging ropes. The production line involves several motors, heating control, tension control, and synchronization control. The stability and precision of the equipment are critical for production efficiency and product quality.

Main Equipment:

1. Extruder: Used for melting and extruding the raw material into a uniform melt.
2. Drawing Machine: Used for stretching the cooled fibers to increase strength and elasticity.
3. Twisting Machine: Used for twisting the stretched fibers into ropes.
4. Winding Machine: Used for winding the finished ropes into coils.

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2. Control System Design

1. Motor Control and Inverter Selection

Motor control is essential for precise production on the line. The speed of each device’s motor must be adjusted in real-time to meet the production process’s requirements. Longi 9000 series inverters will be used to control the speed of each motor.

Extruder Motor Control:

• Motor Power: Typically, 15-55 kW asynchronous motors are selected.
• Inverter Model: Longi 9000 series inverters are suitable for high-power motors, providing precise speed control.
• Wiring Method: The inverter’s input is connected to a three-phase power supply, and the output is connected to the motor terminals via cables, usually using a star connection for stable starting torque and reliability.

Extruder Motor Parameter Settings:

• Frequency Range: 0-60Hz (can be adjusted depending on production requirements, typically set at 30Hz).
• Acceleration/Deceleration Time: Set to 5-10 seconds for smooth starting and stopping, avoiding overload.
• Current Limiting: Set to 120% of rated motor current as protection.

Drawing Machine Motor Control:

The drawing machine is used to stretch the fibers, and its speed is directly linked to the extruder’s output speed. The drawing machine inverter will be synchronized with the extruder inverter.

• Motor Power: Typically, 5-15 kW asynchronous motors are selected.
• Inverter Model: Longi 9000 series inverters.
• Wiring Method: Similar to the extruder inverter, connected via bus for synchronized control.

Drawing Machine Motor Parameter Settings:

• Frequency Range: 0-100Hz to match stretching speed with the extruder.
• Acceleration/Deceleration Time: Set to 5-10 seconds to avoid fiber breakage from fast stretching.
• Speed Synchronization: Use the inverter’s multi-machine synchronization function to keep the drawing machine synchronized with the extruder.

Twisting Machine and Winding Machine Motor Control:

Both the twisting machine and winding machine require precise speed control, especially for tension control under different conditions.

• Motor Power: Twisting machine typically uses 2-5 kW motors, and winding machine uses 5-15 kW motors.
• Inverter Model: Longi 9000 series for precise speed regulation and starting/stopping control.
• Wiring Method: Standard three-phase connection, with the inverter connected to the motor.

Twisting Machine Motor Parameter Settings:

• Frequency Range: 0-60Hz.
• Acceleration/Deceleration Time: Set to 3 seconds for smooth twisting.
• Synchronization Function: Achieved through PLC coordination with the drawing and winding machines.

Winding Machine Motor Parameter Settings:

• Frequency Range: 0-60Hz, closely related to fiber tension.
• Acceleration/Deceleration Time: Set to 5 seconds for uniform winding.

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2. Heating Control System and Temperature Regulation

The heating system in the extruder is crucial for maintaining material quality. Temperature control must be precise. We will use Longi PLC (LX1000 series) along with temperature control modules to monitor and adjust the temperature.

Extruder Temperature Control Design:

• Heating Zones: The extruder has multiple heating zones, each equipped with a temperature control module to monitor and adjust the temperature.
• Wiring Method: The temperature control module’s output is connected to the heater, and the PLC adjusts the temperature using analog outputs (4-20mA).
• Temperature Sensor: Use PT100 sensors with an accuracy of ±0.5°C to provide real-time temperature feedback to the PLC.

Temperature Control Parameter Settings:

• Set Temperature Range: Typically set at 180-220°C for different zones, suitable for PP and PE melting temperatures.
• Temperature Adjustment Strategy: Use PLC’s PID control algorithm to maintain precise temperature, avoiding overheating or cooling, which may cause instability in the material quality.

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3. Tension Control System

Precise tension control is essential during the drawing and winding processes to prevent fiber breakage or uneven winding. We will integrate tension sensors with the Longi PLC to implement real-time tension monitoring and control.

Tension Control Design:

• Tension Sensors: Select high-precision tension sensors like the FMS series, installed at key points on the drawing and winding machines for real-time feedback.
• Control Method: The PLC receives signals from the tension sensors and adjusts the drawing and winding speeds to maintain consistent tension.
• Wiring Method: The tension sensors provide analog signals to the PLC, which adjusts the motor speeds for closed-loop tension control.

Tension Control Parameter Settings:

• Target Tension Range: Set between 0.5-2kg to ensure stable fiber stretching and winding.
• Feedback Method: PLC adjusts the drawing and winding machine speeds based on the tension feedback from sensors.

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4. Synchronization Control Scheme

Synchronization control between multiple devices is essential for smooth production. We will use Longi PLC’s high-speed counters and pulse output features to synchronize devices.

Synchronization Control Design:

• Master and Slave Synchronization: The extruder will be the master device, while the drawing machine, twisting machine, and winding machine will be slaves. The PLC will synchronize these machines via pulse output.
• Wiring Method: The PLC sends pulse signals to all devices using high-speed counters to synchronize their operation.
• Synchronization Adjustment: The PLC adjusts each device’s speed according to the main device’s status, ensuring coordinated operation.

Synchronization Control Parameter Settings:

• Synchronization Pulse Frequency: Set to 50Hz to synchronize all devices.
• Precision Requirements: The PLC’s pulse output precision is set to 1ms to ensure synchronization accuracy.

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3. System Architecture and Wiring Diagram

Below is the basic wiring and architecture diagram for the packaging rope production line control system:

Equipment Connection and Wiring Diagram:

[Raw Material Mixer] → [Extruder] → [Cooling Tank] → [Drawing Machine] → [Twisting Machine] → [Winding Machine]
       ↑                ↑                ↑               ↑
       |                |                |               |
   [Longi PLC] ←→ [Longi 9000 Inverter] ←→ [Temperature Control Module] ←→ [Tension Sensors]

System Architecture Diagram:

              +------------+                +-------------+
              |  Longi PLC  | ←--> [Inverter] ←--> [Motor] ←--> [Device]
              +------------+                +-------------+
                     ↑                            ↑
                  [Sensors] ←--> [Tension Control] ←--> [Heating Control]

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4. Conclusion

By integrating Longi 9000 series inverters, LX1000 series PLCs, and Longi plastic machine configuration software into the packaging rope production line, we can achieve precise motor control, temperature regulation, tension control, and synchronization control, ensuring efficient and stable production. The design is clear and logically sound, meeting the needs of modern packaging rope production lines for automation and intelligence.

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1. Application Background and Industry Pain Points

In enclosed or semi-enclosed environments such as underground parking lots, automobile repair workshops, welding workshops, paint booths, and other industrial sites, harmful gases like carbon monoxide (CO), emitted from vehicle exhaust, fuel combustion, or industrial processes, can accumulate over time. This presents a health risk to workers and affects the quality of air. Therefore, an intelligent, automated ventilation control system is needed to monitor and regulate air circulation in real time.

Traditional ventilation systems mostly run at fixed speeds, which are simple but result in high energy consumption, low efficiency, and slow response to fluctuating CO concentrations. To address these issues, this solution designs an intelligent ventilation system based on Longi 900 Series Variable Frequency Drives (VFD) and RKC PID controllers for automatically adjusting fan speed using PID closed-loop control, ensuring good air quality in a variety of settings.

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2. System Components and Working Principles

1. Key Components

Module Category	Product Selection	Function Description
VFD (Variable Frequency Drive)	Longi 900 Series VFD	Controls fan speed, adjusts airflow rate automatically
PID Controller	RKC CH102 or REX-C100	Receives CO sensor input and outputs control signals (4-20mA)
Carbon Monoxide Sensor	ZE25-CO (Winsen)	Detects CO concentration in real time, outputs analog signals
Ventilation Equipment	Centrifugal Fan or Duct Fan	Regulates exhaust air according to VFD adjustments
Control Panel	Custom-made	Displays status, allows manual/automatic switch

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2. Control Logic and Operation Principles

(1) CO Concentration Detection

The CO sensor (e.g., Winsen ZE25-CO) continuously monitors the CO concentration in the air, typically outputting a 4-20mA analog signal. When the concentration exceeds a set threshold, it triggers subsequent control actions.

(2) PID Controller Adjustment

The RKC PID Controller compares the actual CO concentration with the set target concentration (e.g., 30ppm) and calculates the required adjustment signal using proportional-integral-derivative (PID) logic. It then outputs a control signal (4-20mA).

(3) VFD Speed Regulation

The Longi 900 Series VFD receives the analog control signal from the PID controller and adjusts the fan motor speed accordingly. For example, if the CO concentration is high, the PID controller will instruct the VFD to increase the speed, thereby increasing the airflow for faster exhaust.

(4) Feedback and Protection

The system continuously monitors CO concentration, and when it exceeds a safe level, the fan speed is increased automatically. Once the concentration drops back to a safe level, the fan speed is reduced to the minimum. This process optimizes energy use while ensuring the safety of workers.

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3. Longi 900 Series VFD Advantages

Feature	Description
PID Control Support	Built-in PID control parameters for automatic regulation based on external input
Flexible Analog Input Interfaces	Supports 0-10V, 4-20mA, and other input signals, adaptable to various control needs
High Reliability	Multiple protection features including overload, overvoltage, and overheat safeguards
Energy Efficiency	Wide speed regulation range (0-500Hz), enabling precise fan speed adjustments to reduce energy consumption
Ease of Maintenance	User-friendly interface, easy to maintain, and extend device lifespan

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4. Suggested System Configuration

Name	Model	Quantity	Description
VFD	Longi 900 Series 900-0015G3 (1.5kW)	1 unit	Drives the fan, adjusts speed according to PID control signals
PID Controller	RKC CH102	1 unit	Receives CO sensor signal, outputs control signal (4-20mA)
CO Sensor	Winsen ZE25-CO	1 unit	Detects CO concentration, outputs analog signal
Fan and Motor	YVF2 1.5kW + Centrifugal Fan	1 set	Core of the system, performs exhaust tasks
Control Panel	Custom-made	1 unit	Includes operation buttons, display indicators, emergency stop

Suggested Parameter Settings

For Longi 900 Series VFD, the following parameters are recommended:

Parameter	Description	Suggested Value
F0-00	Command Source	1 (External Terminal Control)
F0-01	Main Frequency Source	2 (AI1)
F5-02	PID Feedback Source	1 (Analog Input)
F5-08	Sensor Type	1 (4-20mA)
F5-01	PID Setpoint	30ppm (Reference Value)
F0-04/05	Acceleration/Deceleration Time	5-10s

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5. System Deployment and Maintenance Recommendations

1. Installation and Layout

• Sensor Installation: CO sensors should be installed in central locations or at the end of exhaust ducts, approximately 1.5-2 meters above the floor, to ensure complete area monitoring.
• PID Controller: Should be installed in a location visible to the operator for easy adjustment of parameters.
• VFD and Fan Installation: VFD should be installed in an electrical control cabinet with adequate ventilation, avoiding high temperatures and humidity.

2. System Debugging and Operation

• Before powering up, verify that the wiring is correct, especially ensuring that the VFD output terminals (U/V/W) are not connected to the mains.
• Set the RKC PID Controller:
  • Setpoint (SV) to 30ppm.
  • Control mode to PID, output signal set to 4-20mA.
• After connecting the CO sensor, adjust PID parameters (proportional, integral, and derivative gains) for optimal system response.

3. Maintenance and Upkeep

Equipment	Maintenance Task	Frequency
CO Sensor	Zero-point calibration and functionality check	Every 6 months
PID Controller	Output signal and display check	Every 12 months
VFD	Heat sink cleaning and electrical check	Every 12-18 months
Fan Motor	Lubrication and current measurement	Every 3-6 months

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6. System Upgrades and Expansion Recommendations

1. Remote Communication Module

The Longi 900 Series VFD supports Modbus RTU communication. Add a remote communication module for cloud-based monitoring, data logging, and alarm notifications, enabling more advanced smart management.

2. Multi-Region Control

For large workshops or parking lots, deploy multiple independent ventilation units, each with its own CO sensor, to control fan speeds regionally, optimizing energy use.

3. Integration of Particulate Matter (PM2.5/PM10) Sensors

Expand the system to monitor and control particulate pollution, ensuring air quality across various industrial processes.

4. Lighting System Integration

Incorporate lighting control, turning on both the lights and the ventilation system when personnel enter a room, and turning them off after a delay once they exit, further reducing energy consumption.

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7. Conclusion and Value Proposition

With the Longi 900 Series VFD, RKC PID Controllers, and CO Sensor Integration, this system enables automatic fan speed adjustment to ensure air quality and worker safety. By utilizing energy-efficient, smart control, this solution meets the needs of environments like workshops, parking garages, and industrial sites, and provides significant benefits in terms of energy savings, safety, and environmental health.

This system is an ideal solution for maintaining high standards of air quality while optimizing energy use in industrial facilities.

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The Fully Automatic Platen Die-Cutting Machine is a specialized device designed for die-cutting and creasing/creasing of flat sheet materials such as cardboard, corrugated paper, and laminated paper. It integrates the traditional “hand press” platen principle with automatic paper feeding, positioning, collecting, fault detection, and safety interlock systems for batch production of color boxes, cartons, wine boxes, labels, hangtags, and some thin plastic packaging products.

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I. Device Principle & Process Challenges

1.1 Basic Process of Platen Die-Cutting

Process Flow:
Paper Feeding → Positioning → Clamping & Conveying → Die-Cutting/Creasing → Waste Removal → Paper Collecting

Key Features & Challenges:

• High Inertia:
  320-ton machine requires the crank-link mechanism to decelerate and stabilize near the top dead center.
• Tight Timing Coupling Between Stations:
  Intermittent transport of the gripper bar is synchronized with the die-cutting stroke; any timing deviation risks paper tearing.

1.2 Control Key Points & Challenges

Key Points	Challenges	Solution Approach
Multi-Axis Synchronization (Feeder+Indexer+Platen)	Mechanical chain + intermittent cam cause rigid coupling; difficult to optimize speed curves.	Retain mechanical spindle; independent VFD speed control for Feeder. Gripper bar position identified via encoder Z-PULSE to avoid costly electronic cam reconstruction.
Registration & Repeatability	Paper stretching/static electricity, gripper bar spring fatigue.	Front/side guides + photoelectric correction; PLC checks X6/X7 every 10 ms, with high-speed interrupt correction.
Pressure Closed-Loop Control	320-ton hydraulic cylinder pressure drift of 2%.	FX3U-4AD module for 4–20 mA signal; PID regulates Y12 pressure-building valve PWM. Set Press OK = 0.95 × Setpoint.
Safety Category 3	Over 20 door switches + light curtains; often bypassed on older machines.	Pilz PNOZ X3 + safety relay dual-loop; real-time link status display on HMI.

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II. System Configuration Bill of Materials

Category	Selection	Key Parameters/Quantity
PLC	Mitsubishi FX3U-80MT/ES-A	80 I/O, transistor sink output; expansion modules: FX3U-4AD-PT-DA, FX3U-485-BD
HMI	Delta DOP-B10S411 (10.4″, 800×600)	COM1→PLC RS-422; COM2→VFD (Modbus-RTU)
VFD	Inovance MD200-11k-4	Supports 0–10 V analog input + RS-485 monitoring
Servo Drive	Leadshine EL7-750 + 0.75 kW Motor	Indexer drive, 5000 ppr encoder
Safety	Pilz PNOZ X3 ×1, SICK Light Curtain ×2	2 N/C 2 N/O outputs, 24 V DC
Low-Voltage Distribution	Schneider NSX80N+GV2, Phoenix 24 V/10 A PSU	—
Sensors	Panasonic CX-400 Series Photoelectric (12), Ultrasonic Double-Sheet Detector ×1	NPN output
Actuators	Airtac 4V210-08 Solenoid Valves (18), HYDAC Pressure Sensor 1.0–25 MPa	—

Electrical Architecture Overview:

┌──── Pilz PNOZ ────► KM1 / KM3 / STO三相380  ▣         └─> MCB → VFD → Main Motor                │                 ┌─ Encoder                ▼                 ▼              PLC FX3U ──485─── MD200 (VFD)                │RS-422                ▼          Delta HMI DOP-B10S411                │                ├── DO → Sol/Contactor                └── AD → Press Sensor

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III. Control Logic & Program Architecture

3.1 Task Allocation

Program Segment	Function	Key Components
P0 – Start/Emergency Stop	Main contactor, E-stop chain	X0, X1, X2 → Y0, Y1
P1 – Paper Feeding & Registration	Feeder VFD, double-sheet detection, front/side guides	X4–X7, X35 → D400 PID, frequency control
P2 – Gripper Bar	Clamping cylinders, servo indexer	Y5, Y6, Y7, M404 interrupt
P3 – Die-Cutting	Platen servo, pressure closed-loop	Y10, Y11, Y12 → D410 PID
P4 – Paper Collecting	Lifting motor, counter	Y14, Y15, D200 piece counter
P5 – Alarm	Tower light, buzzer, HMI alarm codes	X16–X22, Y16, Y20, Y21

3.2 Main State Machine (S-Bits)

• S000 IDLE
• S010 FEED_READY
• S020 REGISTER
• S030 PRESS
• S040 DELIVERY
• S050 PAUSE / FULL
• S060 ALARM_STOP

All transition conditions are annotated in the CSV instruction list.
High-Speed Interrupt M8252 captures front-guide OK signal every 10 ms to set D404 for auxiliary correction.

3.3 HMI Screen Planning

Screen No.	Theme	Key Objects/Components
00	Welcome / Machine Status Overview	Speed gauge, production count, current job
01	Auto Run	Start/Stop, speed setting, graphical timing bar
02	Settings	Front-guide fine-tuning (±0.1 mm), pressure setting (kN), batch stop count
03	Manual/Test Run	Jog buttons, I/O indicators, simulated teaching
04	Alarm	Alarm code, text description, handling guide
05	System	User permissions, I/O calibration, maintenance hours

HMI Macro Example (Front-Guide Fine-Tuning):

; Macro No.11  Front-Guide +0.1 mmREADWORD  d100,   &H0004  ; Read current front-guide position from D100ADD       d100,   &H0001WRITEWORD d100,   &H0004

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IV. I/O Allocation & Program Files

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V. Enhancements & Future-Proofing

Electronic Cam Retrofit

• Replace mechanical spindle with servo + absolute encoder for virtual spindle + electronic scale registration to achieve speeds up to 5,500 sph.

MES Data Interface

• PLC reports production data to ERP via FX3U-ENET-AD module; add QR code scanning for job change on HMI.

Predictive Maintenance

• Connect key bearing and oil temperature sensors to FX3U-4AD; generate maintenance tasks automatically when runtime exceeds limits.

Safety Upgrade

• Replace single light curtains with SIL 2 extended versions for automatic restart inhibition; add safety STO (VFD) to E-stop.

Energy Recovery

• Retrofit main motor with torque-type servo + DC bus feedback for 8–12% energy savings.

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VI. Project Implementation Milestones

Period	Deliverables	Notes
T0+1 Week	Project Initiation & Electrical Scheme Confirmation	BOM, IO list v1.0
T0+3 Weeks	Electrical Cabinet Drawings / PLC-HMI Program Alpha	CAD PDF + 80% program functionality
T0+5 Weeks	On-Site Assembly & Cold Commissioning	IO point-to-point, drive self-learning parameters
T0+6 Weeks	Hot Commissioning Trial Production (10 h)	Speed curve optimization, quality confirmation
T0+7 Weeks	FAT & Documentation Delivery	Chinese/English manuals, source code, backup images

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Key Takeaways Highlighted in Bold:

• Multi-Axis Synchronization: Mechanical spindle retained for cost efficiency; Feeder VFD and encoder Z-PULSE ensure precise gripper bar timing.
• Pressure Closed-Loop Control: PID-regulated hydraulic pressure for consistent die-cutting quality.
• Safety: Pilz PNOZ X3 + safety relay dual-loop prevents bypassing; real-time status display on HMI.
• Future-Proofing: Electronic cam, MES integration, predictive maintenance, safety upgrades, and energy recovery ensure long-term competitiveness.

1. Basic Working Principle of Yarn Winders and Winding Machines

Yarn winders and winding machines are two critical pieces of equipment widely used in the textile industry, primarily for winding yarn from the spinning process into yarn spools. While their operation slightly differs, their fundamental goal is the same: to wind yarn uniformly and efficiently while controlling the tension.

The winding process typically begins when yarn is fed into the winder from the feeding device. The winder, or spool, is driven by a motor that rotates, and as the spool rotates, yarn is gradually wound onto it. The diameter of the spool increases as the yarn is wound, and at this stage, it is necessary to stabilize the yarn’s transport through the yarn feeding device and control the tension. To ensure the quality of the winding, the motor speed of the winder, the speed of the yarn feeding motor, and the speed of the traverse mechanism need to be adjusted. This coordination helps prevent issues such as uneven yarn tension or improper winding.

2. Core Parameter Calculation Methods

In the winding process, critical parameters such as yarn speed, yarn length, and tension directly affect the quality of the winding. To ensure an efficient and stable winding process, it is essential to accurately calculate and set these core parameters.

1. Calculation of Yarn Speed

Yarn speed refers to the linear speed at which the yarn moves through the winding device, typically measured in meters per minute (m/min). Yarn speed directly affects yarn tension and the efficiency of each winding cycle. The calculation formula is: Yarn speed(m/min)=Spool diameter(mm)×π×Chain speed(r/min)1000\text{Yarn speed} (m/min) = \frac{\text{Spool diameter} (mm) \times \pi \times \text{Chain speed} (r/min)}{1000}

Where the spool diameter (D) is the diameter of the yarn spool formed during the winding process, and the chain speed is the speed of the motor. The formula uses π\pi as the constant for calculating the circumference, and 1000 is the conversion factor from millimeters to meters. This formula allows for calculating the actual yarn speed during the winding process.

2. Calculation of Yarn Length

Yarn length refers to the total length of yarn used in each winding cycle. The formula for calculating yarn length is: Yarn length(m)=Yarn weight(g)×9000Yarn Denier(Den)\text{Yarn length} (m) = \frac{\text{Yarn weight} (g) \times 9000}{\text{Yarn Denier} (Den)}

Yarn denier is a unit of yarn density, representing the weight of 9000 meters of yarn. By knowing the yarn weight and denier, we can calculate the required winding length.

3. Tension Control

Tension is one of the most important parameters in the winding process. It directly determines the tightness and uniformity of the winding. Since the diameter of the spool changes during the winding process, yarn tension will fluctuate as well. Typically, when the spool diameter is small, the yarn tension is high, and when the spool diameter increases, the tension decreases.

To maintain stable tension, it is necessary to adjust the motor speeds of the winder and yarn feeder, and the traverse speed, which can effectively prevent the yarn from becoming too loose or too tight. The stability of tension is a key factor in the final yarn quality and affects properties such as yarn strength and elasticity.

3. Key Points for Winding and Yarn Feeding Control

The control of winding and yarn feeding involves several factors, mainly coordinating the motor speeds of the winder, yarn feeder, and traverse mechanism to ensure uniform and orderly yarn placement.

1. Winder Motor Control: The winder motor needs to adjust its speed to accommodate the increasing spool diameter. As more yarn is wound, the diameter of the spool increases, and the motor speed needs to decrease accordingly to ensure that the yarn tension does not become excessive. In this case, the sway frequency function can help adjust the frequency fluctuations, preventing tension fluctuations caused by a constant frequency.
2. Yarn Feeder Motor Control: The primary task of the yarn feeder motor is to transport the yarn from the supply device to the winder. The speed of the yarn feeder needs to be coordinated with the winder motor speed to ensure that the yarn does not become too loose or too tight. The adjustment of the yarn feeder motor speed directly affects the stability of yarn transport.
3. Traverse Mechanism Control: The traverse mechanism’s role is to adjust the yarn’s placement on the spool, ensuring each layer of yarn is laid down evenly. As the spool diameter changes, the traverse mechanism needs to adjust its speed according to preset parameters to maintain the correct yarn placement angle and density.

4. The Mechanism and Nature of Tension Stability

Tension stability is one of the most critical issues in the winding process, as any fluctuation in tension can lead to yarn breakage, slackness, or uneven winding. The stability of tension mainly relies on the following factors:

1. Adjustment of Motor Speed: By adjusting the motor speeds of the winder and yarn feeder, the yarn tension can be kept uniform throughout the winding process. If the motor speed is too high, it may cause the yarn to become too tight; if it is too low, the yarn may become slack.
2. Cooperation of the Traverse Mechanism: The control of the traverse mechanism helps to adjust the yarn’s tension distribution, especially when the spool diameter changes significantly. The traverse mechanism can balance the yarn’s tension in this case.
3. Control of Frequency Fluctuations: As mentioned earlier, the sway frequency function adjusts the motor frequency periodically to stabilize tension and ensure that yarn remains uniform throughout the winding process.
4. Real-Time Feedback and Adjustment: Although traditional winding control is mostly open-loop control, with the advancement of modern control technologies, many systems now integrate real-time monitoring and feedback mechanisms. By monitoring tension changes, the system can adjust motor speeds or traverse speeds to ensure tension remains within a preset range.

5. The Importance of Sway Frequency and Its Implementation

The sway frequency function is crucial in the winding process. By periodically adjusting the frequency fluctuations of the motor, it reduces and controls tension variations, preventing issues caused by frequent tension changes in the yarn. Modern frequency converters are generally equipped with this function, especially in the textile, spinning, and yarn winding industries. The sway frequency function has become an important method of controlling tension.

Implementation of sway frequency usually relies on the internal algorithms of modern frequency converters, which adjust the frequency periodically to simulate or adjust the mechanical motion during actual production, ultimately achieving the optimal tension distribution effect.

6. The Use of KL-626 Controller

The KL-626 controller is a commonly used device for yarn winders. Its primary function is to adjust the motor speeds, traverse motion, and tension control during the winding and yarn feeding process. The following are some key parameters and usage methods for the KL-626 controller:

1. P.01DD Winding Mode: Used to select the winding mode, such as “Continuous”, “Shut-off”, etc. Different modes can be selected according to the production needs.
2. P.02TR Running Time: Controls the running time for each cycle, i.e., the duration of each winding process. This needs to be adjusted according to actual needs.
3. P.03L1 Starting Travel: Sets the starting position of the winder. It should be adjusted based on the length of the spool and the required number of winding layers.
4. P.05F1 Starting Frequency: Sets the motor frequency at the start of the winding process. This parameter determines the initial yarn tension.
5. P.07UT Traverse Speed: Controls the speed of the traverse mechanism. This parameter adjusts the speed at which the yarn is laid on the spool, based on the spool’s diameter and the required yarn placement density.

7. Replacement and Adjustment Ideas

With advancements in technology, modern frequency converters and PLC systems have gradually replaced some functions of the KL-626 controller. The sway frequency function in modern frequency converters can directly control the winder and yarn feeder motors, while the PLC can be programmed to achieve more flexible control. Here are some suggestions for replacement and adjustment:

1. Using Modern Frequency Converters with Sway Frequency Function: Modern frequency converters with the sway frequency function can replace part of the KL-626 controller’s functions by adjusting the frequency fluctuations to stabilize yarn tension, simplifying the control system.
2. Using PLC Control Systems: PLCs can programmatically control the frequency converter’s settings, adjust speeds, and monitor tension. PLCs offer higher flexibility and customizability, which makes them suitable for applications that require customized adjustments.
3. Adjusting Key Parameters: Based on actual equipment requirements, key parameters like P.02 (running time), P.03 (starting travel), and others should be adjusted to ensure that tension is stable during the winding process, avoiding excess tightness or slackness.

8. Conclusion

The control of yarn winders and winding machines involves multiple critical parameters, with tension control being the most crucial. By optimizing the sway frequency function in modern frequency converters, adjusting motor speeds, and regulating traverse speeds, yarn tension can be stabilized during the entire winding process. The KL-626 controller, a traditional specialized controller, sets parameters to control the winding process, but modern frequency converters and PLC control systems have become important alternatives. With the help of these advanced control methods, the efficiency and quality of textile production have been significantly improved.

I. Introduction

Blow molding machines are critical equipment for producing hollow plastic products (such as PE bottles and containers), with processes involving 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 the application of the 590+ drive in PE material blow molding machines, 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 blow molding machines (especially for PE material extrusion blow molding) includes:

1. Extrusion: Plastic pellets are melted through the extruder screw to form a tubular parison.
2. Clamping: The mold closes to clamp the parison.
3. Blow Molding: Air is injected into the parison to expand it into shape.
4. Cooling: The molded product is cooled.
5. Mold Opening: The mold is opened to remove the finished product.

Motor Functions

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

1. Extruder Motor:
   • Function: Drives the screw to control the 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, emphasizing the need for high torque and precise speed control in the extruder.
2. Clamp 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, requiring precise control of the clamping system.
3. Other Motors (such as conveying and blow molding) typically use AC motors or pneumatic/hydraulic systems and are not suitable for the 590+ DC drive.

Motor Specifications (Based on User Input)

• Rated Voltage: 440V
• Rated Current: 25.1A
• Power: 15kW
• Speed: 1500 rpm
• Field: Field current not provided; assumed to use voltage control mode.

Assumption: The extruder motor uses the above specifications, while the clamp unit motor specifications may differ (e.g., 10A, assumed value) and need to be adjusted according to the actual nameplate.

III. Application Design of the 590+ DC Drive

1. Application Positions and Functions

(1) Extruder Motor

• Control Mode: Speed Control Mode (Speed Setpoint).
• Functions:
  • Precisely control the screw speed to ensure uniform melting of PE materials.
  • Maintain stable extrusion through PID control.
  • Use Ramp function for smooth start/stop.
• Implementation: The drive receives a 0-10V speed reference signal from the PLC and feeds back the actual speed via an encoder or DC generator.

(2) Clamp Unit Motor

• Control Mode: Speed Control Mode (Speed Setpoint) or Position Control Mode (if supported).
• Functions:
  • Control the rapid closing and opening of the mold.
  • Ensure precise movements to reduce mechanical shock.
• Implementation: The drive receives open/close commands from the PLC and may use limit switches for position control.

2. Wiring Scheme

(1) Motor Connections

• Extruder Motor:
  • Armature: Connect to the drive’s A1 (positive)/A2 (negative) terminals.
  • Field: If internally powered, no connection is needed; if externally powered, connect to FL1/FL2 terminals (refer to manual).
• Clamp Unit Motor: Same as above; confirm based on actual motor specifications.

(2) Control Signal Connections

• Speed Reference:
  • PLC analog output (0-10V) connected to the A4 terminal (ANIN3).
  • Ensure signal shielding to reduce noise.
• Start/Stop:
  • PLC digital output connected to the C3 terminal (DIGN2, start).
  • PLC digital output connected to the C4 terminal (DIGN3, stop, or use a single signal).
• Feedback:
  • Encoder connected to the drive’s encoder input terminals.
  • DC generator connected to the TB terminal.
• Communication:
  • P3 port connected to the PLC communication interface (e.g., RS-485) for data exchange.

(3) Power Connections

• Main Power: Three-phase AC power (380V or matching voltage) connected to the L1/L2/L3 terminals.
• Control Power: 24V DC connected to the C9 (+24V)/C10 (0V) terminals.

Wiring Precautions

• Use shielded cables to reduce electromagnetic interference.
• Ensure good grounding and compliance with safety standards.
• Refer to the wiring diagram in Appendix L of the manual.

3. Parameter Settings

(1) Extruder Motor

The following parameters are based on the motor nameplate (440V, 25.1A):

Parameter Name	Label	Setting Value	Range	Default	Notes
ARMATURE V CAL.	20	1.0353	0.9800 to 1.1000	1.0000	Voltage switch set to 425V
CUR. LIMIT/SCALER	15	100.00%	0.00 to 200.00%	100.00%	Corresponds to 25.1A
MAIN CURR. LIMIT	421	100.00%	0.00 to 200.00%	200.00%	Adjustable as needed
FIELD CONTROL MODE	209	VOLTAGE	VOLTAGE/CURRENT	VOLTAGE	Voltage control mode
RATIO OUT/IN	210	90.00%	0.00 to 100.00%	90.00%	Initial field voltage ratio
SPEED FBK SELECT	10	ENCODER	Multiple options	–	Assume encoder used
MODE	1	Speed Setpoint	Multiple modes	–	Speed control mode
RAMP RATE (Accel)	2	5.0 seconds	0.1 to 600.0 seconds	–	Smooth acceleration
RAMP RATE (Decel)	3	5.0 seconds	0.1 to 600.0 seconds	–	Smooth deceleration

(2) Clamp Unit Motor

Assuming a current of 10A, other parameters are similar:

Parameter Name	Label	Setting Value	Range	Default	Notes
ARMATURE V CAL.	20	1.0353	0.9800 to 1.1000	1.0000	Voltage switch set to 425V
CUR. LIMIT/SCALER	15	100.00%	0.00 to 200.00%	100.00%	Corresponds to 10A
MAIN CURR. LIMIT	421	100.00%	0.00 to 200.00%	200.00%	Adjustable as needed
FIELD CONTROL MODE	209	VOLTAGE	VOLTAGE/CURRENT	VOLTAGE	Voltage control mode
RATIO OUT/IN	210	90.00%	0.00 to 100.00%	90.00%	Initial field voltage ratio
SPEED FBK SELECT	10	ENCODER	Multiple options	–	Assume encoder used
MODE	1	Speed Setpoint	Multiple modes	–	Speed control or position control
RAMP RATE (Accel)	2	2.0 seconds	0.1 to 600.0 seconds	–	Rapid acceleration
RAMP RATE (Decel)	3	2.0 seconds	0.1 to 600.0 seconds	–	Rapid deceleration

Setting Steps:

1. Enter the configuration mode via MMI (CONFIGURE ENABLE = ENABLED).
2. Set the above parameters, referring to the manual’s menu system.
3. Save the parameters (CONFIGURE ENABLE = DISABLED).

4. Control System Integration

(1) PLC Selection

• Recommendation: Siemens S7-1200 (compact, suitable for small to 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).

(2) HMI Selection

• Recommendation: Siemens KTP700 Basic or Allen-Bradley PanelView Plus.
• Functions:
  • Display extrusion speed, motor current, and fault status.
  • Provide start/stop buttons and speed setting interface.
  • Alarm management.
• Interface Example:
  • Home Page: Display running status, speed, current.
  • Settings Page: Adjust extrusion speed, clamping speed.
  • Alarm Page: Display drive fault codes.

(3) Industrial PC (Optional)

• Recommendation: 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.

(4) Control Logic

• PLC Program:
  • Main Cycle: Execute in process order (extrusion → clamping → blow molding → cooling → mold opening).
  • Extruder:
    • On startup, set speed reference (e.g., 50%) and activate the C3 terminal.
    • On shutdown, deactivate C3 and set speed to 0.
  • Clamp Unit:
    • Before blow molding, send a close command (speed 100%).
    • After blow molding, send an open command (speed -100% or reverse).
• Example Logic (Text Description):
  • Press the “Start” button:
    • Output speed reference (Q0.0, 0-10V) to A4.
    • Activate C3 (Q0.1, start).
  • Clamping phase:
    • Output clamping speed (Q0.2, 0-10V) to the clamp drive’s A4.
    • Activate clamp C3 (Q0.3, start).

5. Electrical Wiring Diagram and Control Schematic

(1) Extruder Wiring Diagram (Text 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 externally powered)[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]

(2) Clamp Unit Wiring Diagram (Text Description)

[Three-phase power 380V] --> [L1/L2/L3] --> [590+ input terminals][24V DC power] --> [C9(+24V)/C10(0V)] --> [590+ control power][Clamp motor armature] --> [A1/A2] --> [590+ output terminals][Clamp motor field] --> [FL1/FL2] --> [590+ field terminals] (if externally powered)[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]

(3) Control Schematic (Text 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] --> [Clamp 590+ A4][PLC] --> [Digital output Q0.3] --> [Clamp 590+ C3][Extruder 590+] --> [Extruder motor] --> [Screw][Clamp 590+] --> [Clamp motor] --> [Mold][PLC] --> [Other controls] --> [Blow molding valve, cooling system]

6. Implementation Steps

(1) Wiring

1. Confirm the power supply voltage (380V or matching).
2. Connect the motor armature (A1/A2) and field (FL1/FL2, if required).
3. Connect the control power (C9/C10).
4. Connect the PLC analog output to A4 and digital outputs to C3/C4.
5. Connect feedback devices (encoder or DC generator).
6. Connect the P3 port to the PLC communication interface.

(2) Parameter Setting

1. Enter the MMI and set CONFIGURE ENABLE = ENABLED.
2. Set parameters such as armature voltage, current limit, field mode, etc.
3. Configure speed feedback and control mode.
4. Save parameters and set CONFIGURE ENABLE = DISABLED.

(3) PLC and HMI Configuration

1. Write the process control program in the PLC.
2. Configure the HMI interface, adding status displays and control buttons.
3. Test communication (PLC with the drive).

(4) Testing and Debugging

1. Power on and check the drive status (no alarms).
2. Start the extruder via the HMI and verify speed control.
3. Test the clamp unit’s opening and closing to ensure accurate movements.
4. Adjust parameters (e.g., Ramp time, PID gain) to optimize performance.

7. Precautions

• Safety: Power off before wiring and comply with electrical safety standards.
• Debugging: Test step-by-step to avoid motor overload or mechanical damage.
• PE Material Characteristics: Ensure extrusion speed is coordinated with temperature control.

8. Conclusion

By applying the Parker 590+ DC drive to the extruder and clamp 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 enable automated control. This scheme is a general design and may require fine-tuning based on specific equipment and processes.

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Introduction

In the production process of textile factories, the napping machine (also known as the wire-drawing machine or yarn-extracting machine), as key equipment, undertakes the important tasks of stretching and homogenizing fibers. It is widely used in processes such as carding and yarn extraction. The Holip HLP-A100 inverter, as a general-purpose vector inverter, with its high reliability, wide range of applications, and rich control functions, can achieve precise control of the napping machine motor. This solution will comprehensively elaborate on the specific application of the Holip HLP-A100 inverter in the napping machine, covering the application positions, wiring methods, parameter settings, control logic, and providing descriptions of the electrical wiring diagram and control schematic. Additionally, equipment such as PLCs, touch screens, or industrial computers can be introduced according to requirements to achieve more advanced control functions.

I. Equipment Situation of the Napping Machine and Motor Function Analysis

The napping machine mainly stretches and homogenizes fibers through a series of rollers (or rolls). These rollers are usually driven by motors, and some roller groups may require independent motors to achieve precise speed control and ensure a constant drawing ratio (yarn-extracting ratio) of fibers between different rollers. The napping machine mainly includes the following key components and motor functions:

• Main Stretching Roller Motor: Assumes the main stretching function and requires variable speed control to adapt to different fiber types and production requirements.
• Auxiliary Roller Motor: Used for auxiliary stretching and fiber conveying, which may run synchronously with the main motor at a fixed speed ratio.
• Conveying Motor: Responsible for conveying fibers from upstream equipment (such as carding machines) to the napping machine and conveying the processed fibers to downstream equipment (such as spinning machines).
• Tension Control Motor: Some high-end napping machines are equipped with a dedicated tension control motor to maintain fiber tension and ensure production quality.

The motors of the napping machine are usually three-phase asynchronous motors with a power range of 1.5kW – 15kW, depending on the machine size and production capacity. This solution is based on the design of a main stretching roller motor with a power of 4kW.

II. Key Features and Specifications of the Holip HLP-A100 Inverter

The Holip HLP-A100 inverter, as a general-purpose vector inverter, is suitable for various motor control needs in the industrial field. Below are its key features and specifications (based on the official manual):

Category	Details
Power Range	0.75kW – 220kW (models such as HLP-A100001143 to HLP-A100022043)
Voltage Range	Three-phase 380 – 440V/440 – 480V, 50/60Hz
Control Modes	Speed open loop, process closed loop, torque open loop
Digital Inputs/Outputs	4 digital inputs (DI1 – DI4), 2 digital outputs (DO1 – DO2), 2 relay outputs (KA – KB, FA – FB – FC)
Analog Inputs/Outputs	VI (0 – 10V/4 – 20mA), AI (0 – 10V/4 – 20mA), AO (0 – 20mA/4 – 20mA)
Pulse Inputs/Outputs	Pulse input (0.001 – 100.0KHz), pulse output (0.001 – 5.0KHz)
Communication Protocol	Modbus RTU (address range 1 – 247, baud rate 2400 – 38400)
Special Functions	Swing function, cascade control, winding control, mechanical braking, multi-speed control, etc.
Environmental Adaptability	Maximum altitude 1000m (output power or temperature must be reduced when exceeding this limit)

This solution selects a model suitable for a 4kW motor from the HLP-A100 series, such as HLP-A100004043 (the specific model needs to be confirmed according to the manual).

III. Inverter Application Solution Design

3.1 Application Position

The Holip HLP-A100 inverter is mainly applied to the main stretching roller motor of the napping machine to achieve variable speed control of the main stretching roller. If the napping machine has multiple roller groups, multiple HLP-A100 inverters can be used, and cascade control can be implemented to achieve synchronous operation between different rollers and ensure a constant drawing ratio.

3.2 Wiring Method

3.2.1 Main Circuit Wiring

• Main Circuit Terminals:
  • R, S, T: Connect to the three-phase AC power supply (380V/50Hz).
  • U, V, W: Connect to the motor output terminals.
  • PE: Grounding terminal, which must be connected to a reliable ground.
• Brake Circuit (if required):
  • +UDC, -UDC: Connect to the brake resistor (the resistance value is selected according to the manual, usually 0.15 – 0.4Ω).

3.2.2 Control Circuit Wiring

• Digital Inputs (DI):
  • DI1: Forward Run.
  • DI2: Stop.
  • DI3: Reverse Run (if required).
  • DI4: Other auxiliary functions (such as emergency stop).
• Analog Inputs (AI):
  • AI1: Speed reference signal (e.g., provided by an external potentiometer or PLC).
• Relay Outputs (Relay):
  • KA – KB: Fault alarm output.
  • FA – FB – FC: Running status indication.
• Communication Interface (RS485):
  • RS+, RS-: Connect to the communication port of the PLC or touch screen.

3.2.3 Wiring Diagram Description

[Three-phase Power Supply] — R, S, T — [Holip HLP-A100 Inverter] — U, V, W — [Main Stretching Roller Motor]
[Ground] — PE — [Holip HLP-A100 Inverter]
[External Control Signal] — DI1(DI2/DI3/DI4) — [Holip HLP-A100 Inverter]
[Speed Reference Signal] — AI1 — [Holip HLP-A100 Inverter]
[Fault Alarm] — KA – KB — [Alarm Light or PLC]
[Running Status] — FA – FB – FC — [Indicator Light or PLC]
[Communication] — RS+, RS- — [PLC/Touch Screen]

3.3 Parameter Settings

Parameter settings are crucial for ensuring the normal operation of the inverter. Below are the typical parameter settings for the main stretching roller motor of the napping machine (based on the HLP-A100 manual):

3.3.1 Basic Parameters

• C01. Configuration Parameters
  • C01.00 Configuration Mode: Set to “Speed Open Loop”.
  • C01.20 Motor Rated Power: Set to 4.0kW.
  • C01.21 Motor Rated Voltage: Set to 380V.
  • C01.22 Motor Rated Current: Set according to the manual or motor nameplate (e.g., 7.8A).
  • C01.23 Motor Rated Frequency: Set to 50Hz.
  • C01.24 Motor Slip: Set according to the motor parameters (usually 1% – 5%).

3.3.2 Reference and Ramp Parameters

• C03. Reference/Ramp Parameters
  • C03.03 Maximum Reference: Set to 50.0Hz (or adjust according to actual requirements).
  • C03.04 Minimum Reference: Set to 0.5Hz (to avoid crawling at low speeds).
  • C03.05 Acceleration Time 1: Set to 5.0 seconds (adjust according to production requirements).
  • C03.06 Deceleration Time 1: Set to 5.0 seconds (adjust according to production requirements).

3.3.3 Digital Input/Output Parameters

• C05. Digital Input/Output Parameters
  • C05.00 DI1 Function: Set to “Forward Run”.
  • C05.01 DI2 Function: Set to “Stop”.
  • C05.02 DI3 Function: Set to “Reverse Run” (if required).
  • C05.10 DO1 Function: Set to “Running Status”.

3.3.4 Analog Input/Output Parameters

• C06. Analog Input/Output Parameters
  • C06.99 AI1 Function: Set to “Frequency Command”.

3.3.5 Cascade Control Parameters (if synchronous control is required)

• C25. App. Functions Cascade Parameters
  • If multiple motors need to be synchronized, the main inverter can be set as the master, and the auxiliary inverters can be set as slaves, with the frequency ratio set.

3.4 Advanced Control Solution: Introducing PLC and Touch Screen

To achieve more advanced control and a user interface, a PLC and touch screen can be introduced. Below is the recommended solution:

3.4.1 PLC Selection

Select a PLC that supports the Modbus RTU protocol, such as the Siemens S7-200 series or Schneider Modicon series. The PLC is responsible for handling logic control, such as start, stop, speed setting, and fault handling.

3.4.2 Touch Screen Selection

Select a touch screen that supports Modbus RTU, such as the Weintek MT8071i series. The touch screen is used for the user interface, providing start/stop buttons, speed setting sliders, status displays, etc.

3.4.3 PLC and Touch Screen Wiring

• The PLC is connected to the inverter via RS485 communication.
• The touch screen is connected to the PLC’s communication port or directly to the inverter (if the touch screen supports direct control).

3.4.4 PLC Program Design

• Use the PLC’s Modbus function blocks to read the inverter’s status (such as running status, output frequency).
• Use the PLC’s Modbus function blocks to write control commands to the inverter (such as start, stop, frequency setting).
• Logic can be added to the PLC program, such as:
  • When the start button is pressed, send the start command after checking safety conditions.
  • When the speed setting changes, update the inverter’s frequency command.

3.4.5 Touch Screen Design

• Main Screen: Display the current speed, running status, and fault information.
• Control Buttons: Start, stop, emergency stop.
• Parameter Setting Page: Allow adjustment of acceleration/deceleration time, maximum/minimum frequency, etc.

IV. Control Schematic Description

Below is a description of the overall control schematic of the system:

[Three-phase Power Supply] — [Holip HLP-A100 Inverter] — [Main Stretching Roller Motor]
[External Control Signal] — [Holip HLP-A100 Inverter] — [PLC]
[PLC] — [Touch Screen]
[PLC] — [Other Auxiliary Devices (such as alarm lights, indicator lights)]

V. Summary and Key Notes

The application of the Holip HLP-A100 inverter in the napping machine can significantly improve production efficiency and product quality. Through precise speed control and synchronization functions, it ensures the uniform stretching of fibers. Below are the key notes:

• Model Selection: Select the appropriate inverter model according to the power of the napping machine motor.
• Wiring: Ensure correct connection of the main circuit and control circuit, paying attention to grounding and shielding.
• Parameter Settings: Adjust parameters such as acceleration/deceleration time and maximum/minimum frequency according to actual production requirements.
• Safety Protection: Ensure that the emergency stop function works normally and comply with relevant safety standards.
• Advanced Control: Achieve more flexible control and monitoring through PLC and touch screen.

Through the implementation of this solution, the efficient operation of the napping machine can be achieved, providing more reliable production assurance for textile factories.

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