GTAKE AC Motor Drives for Copper Wire Wire-Drawing Machine

Copper wire wire-drawing machine takes advantage of copper’s extensibility, uses power to wind and pull the cooper wire, so that the copper wire deforms because of producing pultrusion plasticity forwardly by wire-drawing die, which makes the diameter smaller, achieving the diameter size that we need. Wire-drawing machine consists of two parts: extending wire and rewinding the wire, adjust the stretching and winding up wire speed by the AC motor drive, so as to match both.

Wire-drawing machine is divided into three parts: winding, extending (drawing wire) and rewinding:

  • Rewinding is generally passive rewinding;
  • Drawing wire operates at a fixed speed to draw copper wire;
  • Rewinding revolving speed is adjusted by tension to match wire drawing speed. The working speed of rewinding step decides the production efficiency of the whole wire-drawing machinery. It is also the most difficult part to control for the whole system.
GTAKE AC Motor Drives for Copper Wire Wire-Drawing Machine

According to the process flow of pulling and drawing, the following equipment need to be used when copper bar is stretched to copper wire.

  • Large wire drawing machine: Maximum incoming wire diameter: 8mm. Outgoing diameter between 1.2 to 3.5mm, some equipped with annealing device.
  • Medium wire drawing machine: incoming wire diameter: between 2.6 to 3.5mm. Outgoing diameter between 1.2 to 2.0mm, some equipped with annealing device.
  • Fine wire drawing machine: incoming wire diameter: between 1.6 to 0.8mm. Outgoing diameter between 0.08 to 0.15mm, some equipped with annealing device.
  • Super fine wire drawing machine: incoming wire diameter: between 0.15 to 0.4mm. Outgoing diameter between 0.12 to 0.03mm, some equipped with annealing device.

Control principles of the above-mentioned four pieces of equipment are of the same. Two AC Motor Drives are used to control, so double variable frequency wire-drawing machine, currently, multiple drives can also be used to wind up.

Rewinder: the rewinding is passive, due to the small power rating in winding and rewinding, torque motor is used to wind wire considering the cost.

Currently, wire-drawing machine has the following two control modes

With oscillating bar

Without oscillating bar

  • Use GK620S
  • Use GK820-DE

Wire-drawing machine with oscillating bar

  1. With oscillating bar, the following two can be divided:
  • With feedforward, with rolling diameter calculation:Winding and rewinding revolving speed=main engine linear speed/winding and rewinding diameter/3.14/reduction ratio + PID output; old scheme
  • Without feedforward, without rolling diameter calculation (Main scheme recommended at the moment): Pure PID control, internal treatment by the drive, main engine no need to provide feedforward signal, no need to calculate winding diameter; new scheme

Differences between the two modes:

  • With oscillating bar, this is an old scheme, each drive manufacturer has, which is difficult to use.
  • Without oscillating bar, this is a new scheme, few manufacturers can do this scheme now, the wiring and use of this scheme is simple.

Wire-drawing machine without oscillating bar (Use GK820-ED)

  • Detect the linear speed of constant speed wheel of main engine by proximity switch, as the linear speed setting of winding and rewinding; Detect the linear speed of rewinding by the proximity switch of tachometer wheel as feedback, control the rewinding revolving speed by the built-in PID of drive.
  • Compare with the scheme with oscillating bar, it has the following advantages:
  1. The host and rewinding tension are constant (slip frequency is always set slip frequency), it will not cause changes to the rewinding tension due to with oscillating bar, and the tension can be adjusted anytime (adjust slip)
  2. When the wire drawing material changes, there is no need to adjust the balance weight of oscillating bar.
  3. Cancel potentiometer detection, change to non-contact proximity switch, significantly reducing failure rates and repair costs

Wire-drawing machine without oscillating bar

  • Single Winding

A coiling block to wind, same as general drive

  • Double winding

Two coiling block to wind at the same time, a host drives two motors to wind up, with a slight difference from traditional machine in machinery, the host cone pulley is two sets of mold design.

Advantages of double winding are: in the premise of same investment, it substantially improves production efficiency and greatly reduce the floor space of same two machines, two wire-rewinding machines are independent of each other. When one doesn’t work or in other circumstances, It does not affect the normal operation of the other machine.

GTAKE AC DRIVE

Related Products

GK620 is a general-purpose AC drive with V/Hz and sensor-less vector control. It’s powerful in performance, reliable in quality and optimized in structure. GK620 is widely used in various applications including air compressor, crane & lift, metal processing, mining, mills, food and beverage processing, packaging, conveyor, textile, plastics, fan & pump, etc.

GK820 is the high-performance series which covers an entire range of applications, particularly for demanding ones that require precise speed control, torque control and fast response, etc.

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