1.Industrial Overview

High-precision and high-width-to-thickness-ratio flat steel wires are widely used in aerospace, automotive, and textile industries such as timer springs, missile fuses, antennas, automotive piston rings, and card clothing racks. The steel wire flattening machine is a machine that rolls round steel wires into flat steel wires by flat roller rolling. The flat steel wires rolled by the steel wire flattening machine have the characteristics of high quality and low cost, and are therefore widely used.

2. Process flow and Control Requirements

• Working process

The round steel wire is rolled into flat steel wire by 3 working rollers. The final flat steel wire is rolled up by the winding device after fixed sliding. There is a rocker potentiometer (rocker A, rocker B) between working roller 1 and working roller 2, and between working roller 2 and working roller 3, respectively, to keep the speed of the flat steel wire consistent.

• Control requirements

The speed of the steel wire after each rolling (a total of 3 rollings) must be consistent.

Tension control of the winding device: If the winding speed is too fast, the tension is too high, which is easy to cause wire breakage; if the wire winding speed is too slow, the tension is too small, which affects the production efficiency; the steady speed accuracy requirement is high.

3.Electric Diagram

4.Parameter Settings

Roller 1

Roller 2

Roller 3

Winding

5.Program Features

1. The VFDs controlling the rolling 2 and rolling 3 processes are equipped with pendulum sensors, which are controlled by PID to keep the speed of the flat steel wire consistent after rolling.

2. The VB VFD of the winding device adopts torque control mode, with high speed stabilization accuracy, large starting torque, smooth start and stop process, no mechanical shock, and avoid loose wire and broken wire.

3. All-round protection functions: overload, overcurrent, overvoltage, overcurrent and other protections increase the safety of the system.