In electrical wire and cable manufacturing lines, copper melting furnace systems require stable, precise, and synchronized control of the drive mechanisms and the PLC-based control system.
For production lines that have been in operation for many years, upgrading the control system and replacing legacy drives can improve overall system performance while making maintenance and future system expansion more convenient.
In this project, the system was upgraded using Parker AC20 drives, with PROFINET communication to the PLC, replacing the previous control solution.
1. Copper Melting Furnace System in the Electrical Cable Production Line
In the copper wire production line, the copper melting furnace is responsible for heating the raw material to a molten state and maintaining the molten copper at the required temperature for the production process. The heating system can be designed with multiple voltage levels or power stages to control the heating process and maintain a stable temperature.
Once the copper reaches the required condition and temperature, the molten copper is transferred to the drawing section for wire formation. Two Servo drives are used to control the drawing section, ensuring the required movement and drawing speed for the production line.
From the drawing section, the material is formed into 12 copper wires and fed into the continuous take-up units. The system uses 18 Parker AC20 drives to control 12 continuous take-up units, allowing individual speed control and coordinated operation of the motors.
The entire system is controlled by a new PLC, with the Parker AC20 drives connected to the PLC via PROFINET. The PLC manages speed, operating status, RUN/STOP commands, warnings, faults, and interlocking conditions between the drawing section and the take-up units.
With this structure, the control system is organized according to the following process sequence:
Copper Melting Furnace → Servo Drawing Section → 12 Copper Wires → 12 Continuous Take-Up Units
This solution synchronizes the drawing and take-up processes while providing a centralized control structure that facilitates operation, monitoring, and maintenance.
2. Upgrading 18 Parker AC20 Drives for 12 Continuous Take-Up Units
Downstream of the drawing section, the system consists of 12 continuous take-up units, using a total of 18 Parker AC20 drives to control the motors in each unit.
Each take-up unit has its own control requirements depending on the mechanical configuration and operating method of the production line.
The AC20 drives are integrated into the PROFINET network, allowing the PLC to centrally manage all drives.
Through the communication network, the PLC can perform functions such as:
- RUN/STOP control.
- Speed control.
- Speed reference adjustment.
- Direction control when required.
- Drive status monitoring.
- Warning and fault monitoring.
- Actual speed monitoring.
The use of 18 AC20 drives for 12 continuous take-up units provides a clear control structure and makes it easier to manage each motor during operation.
3. Benefits of Implementing a New PLC
The upgrade project not only replaces the existing equipment but also rebuilds the control system to suit the structure and operational requirements of the production line.
The new PLC provides:
- Centralized control of the entire system.
- Management of 2 Servo drives and 18 Parker AC20 drives.
- Drive communication via PROFINET.
- Monitoring of the operating status of each device.
- Warning and fault display.
- Easier maintenance and troubleshooting.
- Flexibility for future program expansion and modification when required.
In particular, integrating all 18 AC20 drives into the same PROFINET network reduces the amount of individual control wiring and provides a clear communication structure between the PLC and the drives.
4. Conclusion
The copper melting furnace system upgrade for the electrical cable industry was implemented by building a new centralized control system consisting of a new PLC, 2 Servo drives for the wire drawing section, and 18 Parker AC20 drives for 12 continuous take-up units.
The Parker AC20 drives are connected to the PLC via PROFINET, enabling centralized management of speed, operating status, warnings, and faults across the drive system.
This solution provides synchronized control between the wire drawing section and the continuous take-up units while making the production line more convenient to operate, maintain, troubleshoot, and further upgrade in the future.
Contact Us for System Upgrades and Technical Consultation
Parker Vietnam provides site surveys, system design, and control system upgrades for copper melting furnace production lines, including PLCs, Servo drives, Parker AC20 drives, and PROFINET communication.
If your company needs to replace an existing control system, upgrade drives, or rebuild the PLC control system for a copper wire production line, please contact us for a solution tailored to the machine configuration and actual operating requirements.
KY THUAT VIET COMPANY LIMITED – PARKER VIETNAM
Hotline: +84 908 353 714
Email: info@kythuatviet.vn
