Application of SynRM Motor In Water Tank Wire Drawing Machine
Background
With the continuous development of industrialization in China, wire drawing machines are becoming more and more critical in today's wire processing. Especially in the steel wire, copper wire, plastic, bamboo chopsticks, wood, wire and cable industries, they are becoming more and more widely used. The water tank wire drawing machine is an important equipment for metal wire production, mainly drawing metal wire into fine wires of various specifications. The main drive motor of the wire drawing machine is the main energy-consuming device of the wire drawing machine. Most of the motors configured in the existing wire drawing machines are IE2 energy-efficient three-phase asynchronous motors, which have several defects such as low energy efficiency and short life. Low speed control accuracy and high maintenance cost. Next, we will talk about how to use our HCM5 series motors and G6 drivers to optimize the energy efficiency and defects of wire drawing machines.
Equipment Introduction
Wire drawing machines can be divided into metal wire drawing machines, plastic wire drawing machines, bamboo and wood wire drawing machines, etc. according to their uses; they can be divided into straight-in type, water tank type, etc. according to the drawing method, and can be divided into large drawing machines, medium drawing machines, fine drawing machines and micro drawing machines according to the wire diameter. They are all composed of two parts: wire drawing and wire taking-up. The water tank type wire drawing machine (as shown in Figure 1) is a small continuous production equipment composed of multiple drawing heads. Through step-by-step drawing, the drawing heads are placed in the water tank, and finally the steel wire is drawn to the required specifications. It is particularly suitable for drawing high, medium and low carbon steel wires, galvanized iron wires, tire bead wires, hose wires, tungsten, molybdenum, titanium and other alloy wires, steel cords, copper wires, aluminum wires, etc.
Working condition introduction
① Load characteristics: The wire drawing machine extrude metal materials through the drawing die, which belongs to constant torque load. The speed of drawing thin wire is fast, the load torque is small, and the speed of drawing thick wire is slow, and the load torque is large. Therefore, the motor speed regulation range is required to be relatively wide, generally requiring a speed range of about 2 times. And the motor needs to maintain high-efficiency output in a wide speed range and load torque range.
② Speed characteristics: The main drive motor of the wire drawing machine requires a good speed during operation to ensure the uniformity of the wire. The main drive motor and each auxiliary machine need to be synchronized in speed, so the motor needs to have good synchronization.
③ Starting characteristics: When the wire drawing machine starts, the resistance at the drawing die is relatively large, so the motor needs to have good starting ability.
④ Power configuration: The commonly used power configuration adopts a three-phase asynchronous motor + inverter solution. The motor has low energy efficiency, a narrow high-efficiency range, often runs in a low-efficiency area, and has poor comprehensive electricity economy. There is also slip, and load torque fluctuations are prone to speed fluctuations, poor speed synchronization and stability, and poor torque rigidity.
Hiatran HCM5 Motor Control Solutions
After replacing the wire drawing machine with a magnetically assisted synchronous reluctance motor (MSynRM), the following significant performance improvements and energy saving effects can be achieved:
1. Significantly improve energy efficiency and reduce energy consumption costs
Magnetic-assisted synchronous reluctance motors can usually reach IE5 level energy efficiency, which is more than 30% more efficient than IE2 motors. High efficiency results in lower energy consumption under the same power output, thereby effectively reducing electricity bills. MSynRM's high working efficiency allows long-term use on high-load equipment such as wire drawing machines to significantly reduce energy consumption. It is especially suitable for industrial scenarios with long-term, high-power operation.
2. Reduce heat generation and extend motor life
Magnetic-assisted synchronous reluctance motors generate less heat when operating due to the reluctance effect in their design, which reduces the need for cooling systems and reduces the aging rate of the motor's internal components.
Reduced heat generation also means that the overall life of the equipment is extended, maintenance needs are reduced, and the number of wire drawing machine shutdowns is reduced, which helps to improve production efficiency.
3. Higher speed control accuracy and improved product quality
MSynRM can be highly matched with the frequency converter (VFD) and can achieve precise speed control, which is crucial to the stable operation of the wire drawing machine and product quality.
High-precision speed control enables the wire drawing machine to maintain a consistent speed during the wire drawing process, ensuring uniform wire diameter of the finished product, reducing the scrap rate and improving the quality of the finished product. This also improves the stability of the production line and its adaptability to high-precision products.
4. The starting current is lower, reducing the impact on the power grid.
MSynRM starts with a smaller current and can provide higher torque at lower current, reducing the instantaneous impact on the power grid. This is very beneficial for wire drawing machines that need to frequently start and stop or adjust speed.
The low starting current also means that the electrical losses of the motor are reduced, further improving the overall power usage efficiency.
5. Reduce maintenance requirements and reduce operating costs
The design structure of the magnetically assisted synchronous reluctance motor is relatively simple, without brushes and permanent magnets, making it more stable in operation and with low maintenance requirements. These features not only reduce the number of maintenance downtimes, but also reduce maintenance costs and man-hour costs. Because the motor contains no rare earth elements, cost uncertainty caused by material price fluctuations is further reduced.
6. Long-term economic benefits
Although the initial acquisition cost of a magnetic-assisted synchronous reluctance motor may be higher than an IE2 motor, the return on investment is higher through long-term savings on electricity bills, reduced maintenance costs and higher productivity. For enterprises, the savings in operating costs and increased productivity can directly increase profit margins, making them long-term economic benefits.
Actual case
Motor transformation of a steel cord factory
Original solution: Y2-180L-4 22kW-1475rpm asynchronous motor IE2 energy-efficient variable frequency drive
Current solution: Hiatran HCM5 synchronous reluctance motor drive system IE5 energy-efficient variable frequency drive
Conclusion
Replacing magnetically assisted synchronous reluctance motors on wire drawing machines can not only reduce energy consumption, but also improve product quality, reduce maintenance requirements and extend equipment life. Overall, this kind of motor is a more environmentally friendly and economical choice, suitable for various industrial production lines, especially in high-load and long-term operation scenarios.