The drawing machine system is a sophisticated mechanical device that demands precise and high-speed control. This system is specifically designed for drawing gold wire, which requires even greater accuracy and smoothness compared to standard wire drawing machines. The complexity of the system increases due to the need for multiple control devices and seamless coordination between motors. It employs four sets of servo motors, each with real-time data exchange capabilities. The Kinco servo system supports bus communication, making it ideal for handling the fast and accurate data interactions required between the axes.
To meet the system's requirement for rapid motor-to-motor data exchange, we have leveraged the internal firmware of the Kinco servos. This allows the drive to self-calculate and self-control the wire arrangement, significantly reducing the time delay typically caused by traditional systems where the controller calculates wire position before sending it to the drive. This optimization ensures minimal latency and improved performance. Below is an overview of the system.
**Second, System Block Diagram**
**Third, Process Overview**
1. The un-drawn gold wire passes through a resistance device (such as a wooden block) that provides tension and prevents line jumping.
2. The wire then enters the fine drawing groove, where it undergoes multiple stages of drawing using the fine puller wheel and micro-later wheel, gradually reducing its diameter.
3. A grinding tool is placed between the two towers, shaped to maintain proper wire geometry.
4. The attenuated wire passes through a slip wheel, which maintains consistent tension throughout the process.
5. The wire then goes through a speed measurement wheel, which measures the current speed for feedback purposes.
6. Finally, the wire is guided through an intermediate mechanism, a swinging screw rod, and wound onto the winding drum.
**Fourth, System Control Framework**
The main control challenges in the system include:
1. Maintaining constant wire speed for the feed servo.
2. Ensuring precise following control for the adjust servo.
3. Controlling the winding servo at a constant speed (tension), matching the linear speed of the adjusting motor as the reel radius increases.
4. Managing position servo control to ensure even wire distribution on the bobbin.
Given the need for CANopen bus communication, we selected Schneider’s Twido series PLC along with a CANopen module to meet the system’s requirements.
**Fifth, Control Program Details**
1. **Feed Wire Servo – Constant Speed Control**
The feed wire servo operates in Kinco’s speed mode 3, allowing for stable speed control and smooth acceleration/deceleration. This mode is ideal for resisting disturbances and maintaining a steady speed during the wire drawing process.
2. **Adjust Servo – Following Control**
The adjust servo uses Kinco’s -4 mode, which ensures highly accurate and responsive speed following. Any deviation could cause the gold wire to break, which is not acceptable. This mode allows dynamic adjustment of the gear ratio to maintain ±5% fluctuation in tension.
3. **Winding Servo – Constant Speed (Tension) Control**
This is the most critical part of the system. To prevent wire collapse and ensure smooth winding, the linear speed of the winding motor must match that of the adjusting motor. Instead of using a tension bar, this system directly uses a speed measurement wheel for feedback. We collect the speed signal from the wheel, compare it with the adjusting motor’s speed, and use PID control to adjust the winding speed. Additionally, we factor in the number of winding layers to maintain accuracy as the reel diameter increases.
4. **Position Servo Control**
The position servo ensures even wire placement on the bobbin. Proper commutation is essential to avoid errors. The Kinco servo’s absolute positioning mode handles this effectively, ensuring accurate and smooth operation.
**Sixth, Conclusion**
The system has been in production for over two months and has shown excellent performance. It can reach up to 400 rpm when drawing three wires, which is nearly five times faster than machines using a tension rod feedback loop. The surface quality of the drawn gold wire is smooth and meets all customer specifications.
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KonRun Intelligent Machinery(Ningbo) Co., Ltd. , https://www.konrunmachine.com