In the wire and cable manufacturing industry, the main pulling assembly (Main Drive) of a copper rod breakdown machine is always considered the ‘heart’ of the entire production line. An unstable control system not only causes wire breakage and material waste but also reduces the lifespan of high-capacity motors.
Recently, our engineering team successfully commissioned and handed over the project: Upgrading the main drive control system using the Parker DC598P external stack controller integrated with Encoder feedback for a 510kW DC motor. The project has completely resolved the challenges of speed synchronization and tension optimization for a large-scale cable manufacturing plant.
1. Technical Challenges of the 510kW Main Drive on Copper Rod Breakdown Machines
Heavy-duty industrial copper rod breakdown machines operate with massive moments of inertia. With a DC motor capacity of up to 510kW, the rated current can reach between 1000A and 1200A.
After years of operation, the plant’s legacy control system had degraded and revealed several critical limitations:
-
Jerky Startups: Speed feedback relying on armature voltage or obsolete tachogenerators (Tacho) lost accuracy at low speeds (during wire threading/inching). This caused speed fluctuations and frequent copper wire breakages.
-
System Desynchronization: The Line Speed signal generated by the Main drive was highly susceptible to noise. This prevented downstream slave units—such as the Capstan, Dancer, Spooler, or Coiler—from precisely calculating their tracking speed (Slave speed).
2. Optimized Solution Featuring the Parker 598P External Stack Controller
To handle the massive current demands of the 510kW motor in the most cost-effective and reliable manner, utilizing the Parker DC598P External Stack Controller paired with the existing high-power thyristor stack was the ultimate choice.
Leveraging the Intelligent “Brain” of Parker SSD The Parker 598P inherits the entire software platform, keypad interface, and advanced function block programming from the legendary Parker DC590P series. The unit acts as the central command, processing firing algorithms to trigger external thyristors for seamless motor operation.
Advanced 4-Quadrant (4Q) Regenerative Control The 4Q technology on the DC598P series provides precise control over both rotational directions while enabling highly efficient regenerative braking. The kinetic energy generated during the deceleration of heavy mechanical components is fed back into the power grid, substantially cutting down energy costs for the plant.
3. Core Technologies Integrated into the Project
-
Ultra-Precise Speed Control via Encoder Feedback: We integrated an expansion card and configured the drive to run on Encoder Feedback mode. By tracking continuous pulses in real-time, the Parker DC598P locks the speed profile and maintains excellent torque even at zero speed. Startup jerks during machine acceleration have been completely eliminated.
-
Smoothing the Master Line Speed – The Backbone of the Line: The Main drive serves as the Master that provides the reference line speed for the whole system. The Line Speed signal transmitted to subsequent stages is now flawlessly smooth and precise, enabling: * The Capstan: To track the reference speed at a fixed ratio without any wire slippage. * The Dancer: To maintain a perfectly stable equilibrium position, eliminating erratic swinging. * The Spooler / Coiler: To execute precise diameter calculations combined with PID trimming, ensuring finished coils are wound evenly, tightly, and without deformation.
4. Key Project Outcomes
The control panel upgrade using the Parker DC598P for the 510kW motor has delivered results that exceeded the client’s expectations:
-
20% Productivity Increase: By minimizing wire breakage incidents, machine downtime was reduced to an absolute minimum.
-
Comprehensive Motor Protection: The intelligent Field Control system and thermal protection interlocks (PT100, stack thermal relays) are tightly integrated, ensuring absolute safety for the 510kW motor.
-
User-Friendly Operation: An intuitive control interface allows operators to easily monitor and diagnose faults directly on the Parker keypad.
Reliable Provider for Genuine Parker 590P / 598P Solutions and Retrofits
Are you looking for technological upgrades for your wire drawing machines, plastic extruders, or high-capacity DC drive systems in the cable industry? Do you need expert troubleshooting or advanced configuration for Eurotherm/Parker DC drives?
Contact us today to have our team of highly experienced field engineers survey your site, consult, and deliver the most cost-effective solution for your plant!
-
Hotline: +84 908353714
-
Email: info@kythuatviet.vn
