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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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User Guide for Parker Servo System TWIN5NS(TWIN-N/SPD-N) Series

The Parker servo system TWIN-N/SPD-N series is a high-performance servo drive system widely used in industrial automation, robotics, and precision control applications. This guide provides detailed instructions on how to perform jog testing, position mode control, electronic cam functionality, and troubleshooting for this system.

TWIN5NS physical picture

1. Jog Testing

Jog testing is a crucial step in the calibration and verification of servo systems. Here’s a detailed guide on how to perform jog testing:

Wiring Steps:

  • Power Connection: Connect the three-phase power supply lines L1, L2, and L3 to the drive’s terminals 1, 2, and 3, respectively. For single-phase or DC power supply, refer to the user manual for the appropriate wiring diagram.
  • Motor Connection: Connect the motor’s U, V, and W phases to the drive’s terminals 5, 6, and 7 (Motor I). For dual-axis drives (TWIN-N), connect the second motor’s U, V, and W phases to terminals 9, 10, and 11 (Motor II).
  • Encoder Connection (if used): For incremental encoders, connect the A+, A-, B+, and B- signal lines to terminals 13, 14, 15, and 16, respectively. For sine/cosine encoders, connect the Sin+, Sin-, Cos+, and Cos- signal lines to terminals 6, 7, 8, and 9, respectively.
  • Control Signal Connection: Connect the 24V control power supply to terminals 24 and 48. Connect the analog reference input to terminals 1 and 2 (Rif. AUX + and Rif. AUX -). Connect the JOG operation buttons to digital input terminals (e.g., IN0, IN1) for start, stop, and direction control.

Parameter Settings:

  • Initialize Parameters: After powering on, set the drive to default parameters using the keypad. Set b99.7 and b99.13 to 0, issue command b99.12, and save the settings (b99.14 and b99.15).
  • Set Motor Parameters: Input motor parameters such as pole count (Pr29), rated speed (Pr32), rated current (Pr33), encoder pole count (Pr34), motor impedance (Pr46), and inductance (Pr47).
  • Set Feedback Type: Configure feedback parameters based on the encoder type (e.g., b42.9, b42.8, b42.7, b42.6).
  • Adjust Speed Loop Parameters: Set the integral gain (Pr16) and damping (Pr17) of the speed loop, adjusting based on system response.
  • Set Acceleration/Deceleration Time: Configure acceleration and deceleration times (Pr8, Pr9, Pr10, Pr11).
  • Set Limiting Parameters: Set overspeed limit (Pr13), high-speed limit (Pr14), low-speed limit (Pr15), and peak current (Pr19).

Jog Operation Procedure:

  1. After powering on, start the JOG operation by pressing the corresponding buttons. One button can start the motor in the forward direction, and another can start it in reverse.
  2. Releasing the button should stop the motor immediately or according to the set deceleration.

Open-Loop Mode Testing:

In open-loop mode (without an encoder), the drive operates the motor using V/F control by varying the frequency of the input voltage. Set the motor type to asynchronous (Pr217 = 1) and input related parameters such as base speed (Pr218), slip (Pr219), and magnetizing current (Pr220). In this mode, the drive estimates the motor’s speed and position by detecting the back EMF.

2. Position Mode Forward and Reverse Control

Position mode control is commonly used in servo systems to precisely control the motor’s position. Here’s how to implement forward and reverse control in position mode:

Wiring Steps:

  • In addition to the power and motor connections, connect a position feedback device (e.g., an encoder) to the drive’s corresponding terminals.

Parameter Settings:

  • Set Position Mode: Select the position mode in the operation settings (e.g., Pr31 = 13 or 14).
  • Set Position Parameters: Configure target position (e.g., Pr62:63), speed (Pr8, Pr9), and acceleration (Pr10, Pr11).
  • Enable Position Control: Ensure the position feedback device is correctly connected and calibrated.

Forward and Reverse Control:

Control the motor’s forward and reverse rotation by setting the target position to positive or negative values. For example, a positive target position will rotate the motor forward, while a negative value will rotate it in reverse.

3. Electronic Cam Functionality

The electronic cam function is an advanced feature of servo systems used for complex motion control. Here’s how to implement it:

Implementation Steps:

  • Set Electronic Cam Parameters: Select the electronic cam mode in the operation settings (e.g., Pr31 = 14). Configure the cam table parameters, such as position, speed, and acceleration.
  • Configure Cam Table: Set up the data points in the cam table according to the motion requirements.

Using CAN Protocol:

  • CAN Wiring: Connect the CAN communication lines to the drive’s CAN interface terminals.
  • Set CAN Parameters: Configure the CAN communication speed (e.g., Pr48) and CANopen address (e.g., Pr49).
  • Configure CAN Communication: Set up the data frames and control words for CAN communication according to the user manual.
TWIN5NS functional structure diagram

4. Troubleshooting Fault Codes

Servo systems may encounter various faults during operation. Understanding fault codes and how to handle them is crucial for maintaining system stability. Here are common fault codes and their handling methods:

  • Overcurrent Fault (Pr23 = 1): Check the motor and cable connections, and ensure the load is within rated limits.
  • Overvoltage Fault (Pr23 = 2): Verify the power supply voltage and ensure it is stable.
  • Overheating Fault (Pr23 = 3): Check the drive and motor cooling, and ensure proper ventilation.
  • Encoder Fault (Pr23 = 4): Inspect the encoder connections and signals, and ensure the encoder is functioning correctly.

Handling Procedure:

  1. Identify the fault code and refer to the user manual for the fault description.
  2. Inspect the relevant components and connections based on the fault description.
  3. After resolving the fault, restart the system and monitor its operation.

Conclusion

The Parker servo system TWIN-N/SPD-N series is a powerful and versatile servo drive system. By following the correct wiring and parameter settings, users can perform jog testing, position mode control, and electronic cam functionality. Understanding fault codes and their handling methods ensures the system’s stable operation. This guide provides comprehensive instructions to help users effectively utilize this servo system, enhancing work efficiency and control precision.