Copper wire annealing mill
This equipment rolls round copper busbars into square flat copper wires through multiple rolling mill passes. The rolling process also involves multiple annealing processes, and finally the copper wires are wound up and precisely coiled into rolls.
Process requirements
The tension adjustment for threading should be quick and steady to ensure smooth threading without breaking the thread.
During acceleration and deceleration, the tension quickly reaches the target position and remains stable.
Ensure the width and thickness of the wire are within the tolerance range.
The ribbon cable needs to be precisely aligned, with each cable neatly connected to the next, without any tangling.
The upper and lower rolls are fully synchronized
The annealing and rolling mill functions can be turned on or off at will.
System Composition
The entire system consists of four parts: active wire feeding, rolling mill annealing unit 1, rolling mill annealing unit 2, and take-up and wire laying unit. The entire system adopts a distributed layout, with the rolling mill annealing unit and the take-up and wire laying unit each operating independently. The entire equipment is composed of 3 PLCs: 2 for rolling mill annealing and 1 for take-up and wire laying. Human-machine interaction is completed by a single HMI.
Active wire feeding: The system uses an EM730 frequency converter, which has built-in winding and unwinding functions. The advanced feedforward PID algorithm ensures fast wire feeding response and stable tension at steady speed.
The rolling mill annealing unit consists of two rolling mills and an annealing unit. Each rolling mill's upper and lower rolls are controlled by two servo motors, and each mill also has a transverse stepper motor that automatically moves according to the length of the rolls to reduce wear. The annealing process uses short-circuit annealing with a dedicated sinusoidal annealing controller. The annealing output voltage and frequency are adjustable in real time, up to a maximum of 16kHz. The copper wheel frequency converter uses the EM730 series, which has built-in winding and unwinding functions.
Wire winding and unwinding unit: This system consists of a wire winding servo motor, a dedicated EA180 servo motor for winding and unwinding, a bow belt servo motor, and a traction frequency converter.
Sine scheme
System advantages
01. Modular Design and Assembly
The modular design significantly improves the ease of equipment assembly.
02. PLC Built-in Algorithms and Functions
The PLC has a built-in precision wiring algorithm and supports tapered discs; at the same time, the PLC also has a built-in roll tension control algorithm.
03. Servo control of upper and lower rolls
The upper and lower rolls operate in position mode and are controlled by a single pulse port to ensure complete synchronization between the upper and lower rolls.
04. Short-circuit annealing process
Short-circuit annealing simplifies the mechanical structure and avoids isolation issues.
05. Annealing voltage automatically adjusts with speed.
The equipment maintains optimal annealing results at different production speeds.
06. Automatic wire diameter adjustment function
During the production process, it can automatically adjust the wire diameter in real time according to product requirements and actual production conditions. This allows it to meet the production needs of products with different specifications, reduces the scrap rate caused by improper wire diameter adjustment, and improves production efficiency.
07. The frequency converter has built-in winding and unwinding functions; dedicated servo motor for winding and unwinding.
Application parameters can be set with a single click, reducing the burden of programming for engineers.
08. Automatic adjustment of roll movement
Automatic adjustment significantly extends the service life of the rolls, reduces equipment maintenance costs and downtime, and improves the overall operating efficiency of the equipment.
