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AC90 Professional Solutions for Sizing Machine

Because the interfiber bonding force of greige yarn is not strong and there is too much hair on the surface, it is difficult to weave directly. In order to improve the weavability of warp yarn on the loom, people adopts sizing machine to coat the yarn surface with a layer of serosa. It will effectively increase the wear resistance and reduce the rate of breakage, so the weaving can run more smoothly as the yarn is strong enough to bear the repeated friction, stretch and bend on ding, heddle, reed.

Sizing machine can be divided into various types by the sizing methods, including shaft type sizing machine, sizing-dyeing machine, warping-sizing machine, warping-drawing-sizing united machine and so on.

textile industry

Part 1. Disadvantages of Traditional Sizing Machine

1. Winding and moulding is not satisfactory

2. Low productivity

3. High maintenance cost

The traditional equipment adopts slip motor and mechanical friction plate as the winding mode. When the device detects excessive tension, it will increase the rewinding friction in order to adjust tension. This will cause friction plate damage due to heat. According to our customers’ introduction, the winding sections need to be repaired every 2 months which costs about $60.

Part 2. Advantages of Using Veichi AC90 on Sizing Machine

If you apply AC90 tension control VFD for controlling your sizing machine, the productivity will be greatly enhanced and the equipment maintenance cost will be decreased also.

1. Steady tension control

The traditional equipments control winding via increasing or decreasing friction method that the control accuracy is low. If you apply our AC90 tension control frequency inverter for controlling the sizing machine, the tension control accuracy will be highly improved (=±3%). Additionally, it keeps the whole system running more smoothly.

2. Perfect moulding effect

The traditional sizing machine cannot control the taper tension, so the moulding effect is unsatisfactory. However, Veichi AC90 has been built-in with taper computing function which can ensure perfect moulding effect.

3. Adjust speed and tension separately

With this function, people can operate it conveniently.

4. Improve the producing technique

As the sizing machine is usually working in hot and humid environment, so our AC90 has been specially developed with anti-dust and moisture-proof design.

5. Easy to debugging

AC90 is designed with intuitive user interface and personalized parameter setting mode, which makes the operation and debugging pretty easy.

Part 3. Wiring Layout

wiring layout

Part 4. Debugging Steps

1. Remove the motor load, enter the motor parameters into AC90 VFD, start self learning of motor rotation.

2. Get the exact motor parameters and the mechanical reduction ratio of winding side.

3. Input parameters according to the wiring diagram.

4. Adjust tension gradually from small to large to find the required tension value.

Part 5. Parameter Setting

1. Parameters of AC80C for traction


Function Code


Function Name


Recommended Setting

F0.00

Control mode

0


F0.01

Speed/torque control mode

0


F0.02

Command running channel

1


F0.03

Main frequency given channel

7


F0.14

Accelerating time 1

5


F0.15

Decelerating time 1

5


F2.06


Multi-function terminal X7

10


F2.07

Multi-function terminal X8

11


F3.22

A01 output option

1


F3.23

A02 output option

1


F3.26

A02 signal selection

1

 

    2. Parameters of AC90 for winding

 

Function Code


Function Name


Recommended Setting


F0.00

Control mode

0


F0.01

Speed/torque control mode

1


F0.02

Command running channel

1


F0.03

Main frequency given channel

4


F0.14

Accelerating time 1

0.5


F0.15

Decelerating time 1

1


F2.00

Multi-function terminal X1

1


F2.01

Multi-function terminal X2

56


F3.11

AS lower limit set

8


F9.00

Tension setting source

0003


F9.03

Tension    number given

According to actual condition


F9.05

Taper tension coefficient

According to actual condition


F9.11

Winding diameter computing method

1


F9.13

Winding diameter

According to actual condition


F9.21

Winding diameter computing cut-off frequency

5


F9.25

Linear velocity input source

2


F9.26

Maximum linear velocity

According to actual condition

 

F9.27

Winding diameter computing minimum linear velocity

According to actual condition

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AC90 Frequency Inverter on Dye Jigger

Abstract: In dye jigger control, the PLC with double frequency inverter is simple in configuration and excellent in control performance, which can reduce system cost. This article describes the application details of AC90 series high-performance vector inverter on dye jigger.

1. Introduction

Currently, in textile processing market, cloth dyeing is an important step. Relevant textile processing such as fabric bleach, color and surface pressure grinding can be realized by Dye jigger. Dye jigger control requires automatic counting, automatic turning and auto-stop (emergency stop and stable) and other functions. Throughout the processing, the tension and speed of the cloth should be constant, which requires a higher level of control for the entire control mechanical transmission system.

dye jigger working

2. Dye Jigger Processing

The mechanical outline drawing of Dye jigger is as follows:

The jigger uses two three-phase induction motors and the reducer drags the roller to do the cloth dyeing. When the dye jigger works, one central axis of curl controls the system. The finished cloth would first be rolled onto one roller mounted, and there is proximity switch for counting on the drum shaft (ie, the proximity switch generates a pulse when rolling a cycle), then the tension controller of the dye jigger would count the value of the next piece of cloth.

When up rolling is over, manually pull one end of the cloth through the dye cell and shaft to another roll and wrap it tightly, then start the dye jigger and the fabric dyeing starts. In this case the two rollers move in the same direction, and the pulling tension should be constant and the time when the cloth passes through the dye should consistent. This is a drive control system without line speed feedback or linear speed feedback. Therefore, the output frequency and the output torque of the unwinding frequency inverter should be adjusted unwinding inverter to achieve the unique requirements.

3. Dye Jigger Control

Dye jigger control diagram is as follows:

dye jigger control system

PLC is the main controller of the dye jigger and touch screen is the user interface, which mainly completes the settings of cloth tension, line speed, cloth thickness, and the calculation of running frequency of the winding motor and the output torque of the unwinding motor as well as the control of automatic U-turn, automatic parking and other related logic operations. 485 communication (Modbus RTU communication protocol)is adopted between the drive and the controller. From the control schematic: two same frequency drives work in the VC with PG mode. PLC controller would record the number of cloth when the cloth is on the roller and then the cloth thickness would be measured by operators, and this measured value would be inputted to the controller to accurately calculate the diameter of the roller based on the thickness and number of turns of the cloth. Real time radius can be easily obtained by this thickness integral method and the error is small. PLC can accurately calculate the corresponding torque (winding motor) and matching frequency (unwinding motor) based on real-time turning radius, user-set tension and line speed. And the calculated results would be transmitted through 485 serial communications to AC90 frequency inverter as the basic parameters of the winding motor and the unwinding motor, thus ensuring the constant linear speed and constant tension control.

4. System Features

According to the work principle of the dye jigger, the motor on unwinding side is always in power generation state and the usual practice method is using braking resistor and braking unit to consume the electricity power in the form of heat. For dye jigger, which works in power generation state for such a long-term, this way is a great waste of energy and the electrical control cabinet space is also occupied. Frequency converters especially AC90 series high-performance vector inverter can easily support the common DC bus, and when two inverter DC buses directly in parallel, when the dye jigger works, the power generated during unwinding braking would be transmitted back to the winding motor by the parallel buses, so that the power can be fully used, which greatly improves the efficiency of energy. But in fast stop when two motors are in power generation state, and one of the frequency converter is still in parallel with a braking resistor, of which the work time is short and the energy consumption is small, mainly to prevent over voltage fault when parking the drive system.

5. Conclusion

Compared with DC speed control system, AC90 high-performance vector control inverter has higher performance for controlling the dye jigger, which provides an excellent solution for the product upgrading of dyeing industry.

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