Feature Drives, controls & transmissions Drives keep yarn spinner on the ball
highly accurate control and improved product quality.
In the new control arrangement, 11kW geared motors and associated gearboxes were fitted on the scribbler, carder and eccentrics sections, along with an additional kW motor and gearbox on the doffer. The gearboxes ensure that the correct power is deliv- ered to the rollers while allowing the use of a smaller motor. The AC drives are also run at 4 Hz, allowing further energy savings.
ABB low voltage AC drives are proving to be highly energy efficient for a woollen yarn spinner, Milliken
ABB low voltage AC drives are set to save a woollen yarn spinner nearly £27,000 a year in energy costs
T
he project was completed by Tathams, a specialist in the con- trol of textile machinery. Tathams’ customer, Milliken, produces cloth for use in tennis balls and billiard tables and was using eddy current drives to power and control its four carding engines. These operate on the principle of a slipping clutch for speed variation. This has the disad- vantage that the motors are turning continuously, even when the machine is not in production, making them extremely inefficient - although the motors were turning for over 7,000 hours, only around 1,620 hours of this time were spent in actual production. The original set up used a 15kW
motor, a 25kW motor and two 7.5kW “Tandem Motors” to drive various sec- tions of the machine. These motors where also driving the machine sec- tions directly, shaft to shaft, meaning that the motors where continually run- ning at full load current and some- times overheating.
The new system uses 11kW AC drives and motors, reducing the on time, when the motors are switched on, to just over 3,500 hours. Together with the reduced power usage, the solution achieved yearly energy sav- ings of 540,000kWh. This has reduced the energy bill for the machines by
£27,000, while cutting CO2 emissions by 292,000kg/year. Payback time for
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the system was just over 10 months. Tatham’s engineers conducted an energy survey and designed a new drive system based on four ABB machinery drives using ABB Direct Torque Control (DTC). DTC allows complete synchroni- sation of the machine sections, giving
The low voltage AC drives display data that inform users of the On Time, when the motors are switched on, Run Time, when the motors are driving the rollers, and Kilowatt Hours Used, making it easy to compare the opera- tion with the previous situation. The new motors also run cooler than the previous set-up, resulting in reduced maintenance and improved reliability. ABB is a leader in power and
automation technologies that enable utility and industry customers to improve their performance while low- ering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 135,000 people.
ABB T: 01925 741 111
www.abb.co.uk/energy Enter 316
Breakage problem resolved for rope factory
SMV inverters, the 10-station winding machine used in the pro- duction of polyester rope, caused major headaches with poor product quality and the unplanned downtime needed to repair breakages. Retrofitting the drives has achieved constant smooth tension in the rope strands, even during speed changes, and elimination of rope breaks. The plant operator, located in Poland, turned to the local
A
Lenze agency with a requirement for an integrated solution that would cut out the downtime, eliminate manual adjustments and produce a high quality product that is evenly wound. The retrofit solution provided was based on the SMV inverter, a high performance sensorless vector drive ideal for dynamic speed control. In this case, the IP31 version was used for mounting in a cabinet, but the SMV is also available with IP65 enclosure for decentralised installation. Each of the 10 stations has a dancer roll and position signals from there are input to the integrated PID processor in the drive. Here the processor compares actual signals with a set point and finely adjusts the pull speed to compensate for any errors. By doing so the inverter maintains a steady tension in the rope strand resulting in wound reels of rope that are consistent in shape, an obvious sign of high quality. Furthermore the steady tension has eliminated rope strand breakages and the expensive downtime associated with them. The SMV range of Lenze inverters is available for single phase input 0.37 to 2.2kW and three phase 0.37 to 45kW. Availability is from stock with communication options such as CANopen, PROFIBUS, EtherNet/IP and DeviceNet. All SMV inverters feature a plug-in memory chip that holds all the drive parameters meaning that reprogramming can be done in seconds, even without power. The drives have approvals for use worldwide. Lenze
T: 01234 753200
www.lenze.com Enter 317 MAY 2012 Factory Equipment
Lenze SMV frequency inverter has solved a breakage problem for a European rope manufacturer. Prior to installation of the
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