1 Introduction
China is the world's largest elevator producer, and with the further development of urbanization, the elevator industry has maintained a high growth rate. Due to its advantages such as simple structure, convenient installation, high low-frequency torque, stable speed, and energy saving, permanent magnet synchronous gearless traction machines have surpassed traditional induction motors to become the mainstream configuration for traction machines.
While permanent magnet synchronous gearless traction machines offer numerous advantages, the lack of a reduction gear means that even slight changes in motor speed can significantly impact passenger comfort, especially during elevator start-up. The moment the brakes release, the elevator can easily slip, severely affecting start-up comfort. To improve comfort, a weighing device is typically used. The weight difference between the car and the counterweight is pre-calculated and fed back to the drive controller, which can then output a torque in advance, achieving a smooth elevator start. Currently, most permanent magnet synchronous gearless traction machine elevators use a weighing device to achieve smooth start-up.
Using a weighing device to achieve smooth elevator starts presents obvious problems. Firstly, it increases system costs; secondly, it increases the difficulty of commissioning and the complexity of maintenance. How can a smooth start be achieved in a permanent magnet synchronous gearless traction machine elevator without adding a weighing device? The HD5L elevator-specific drive controller from Shenzhen Haipumont Technology Co., Ltd. can effectively achieve smooth starts in permanent magnet synchronous gearless traction machine elevators without a weighing device.
2 HD5L Technical Features
The HD5L elevator-specific drive controller launched by Shenzhen Haipu Monte Technology Co., Ltd. is a dedicated drive controller developed for the elevator industry. Focusing on the needs of the elevator industry, it combines advanced motor control technology with elevator control functions. It features smooth start-up without load, S-curve acceleration and deceleration, flexible start-stop timing logic, and comprehensive elevator fault protection, which can meet the application requirements of various synchronous and asynchronous traction machines.
2.1 Multiple elevator control operation modes
(1) Terminal analog signal operation mode
The elevator controller calculates the current running direction and speed of the traction machine based on the elevator control logic, and transmits them to the HD5L in digital and analog form, respectively. The HD5L then controls the traction machine to run according to the controller's commands and speed.
(2) Terminal multi-speed operation mode
The elevator controller calculates the current running direction and target speed of the traction machine based on the elevator control logic and sends them to the HD5L in digital form. The HD5L receives the target speed in multi-speed mode, calculates a smooth speed curve based on the set S-curve parameters, and controls the operation of the traction machine.
(3) SCI communication speed operation mode
The elevator controller calculates the current running direction and target speed of the traction machine based on the elevator control logic and sends it to the HD5L via communication. The HD5L receives the target speed in multi-speed mode, calculates a smooth speed curve based on the set S-curve parameters, and controls the operation of the traction machine.
2.2 Advanced motor control technology
The HD5L employs advanced vector control technology, enabling high-precision control of both asynchronous and synchronous traction machines. It can also achieve self-tuning of the static parameters of both asynchronous and synchronous traction machines.
2.3 Achieving weightless smooth start-up of permanent magnet synchronous gearless synchronous traction machine
When using a sine and cosine encoder as a speed feedback device, the HD5L employs a unique algorithm to ensure that the traction machine does not slip when the brake is released during motor startup, achieving a smooth start for the permanent magnet synchronous gearless traction machine without the need for a weighing device.
2.4 Other elevator control functions
The S-curve function provides comprehensive elevator fault protection and flexible start/stop timing logic.
3 HD5L No-Weighing Application Cases
3.1 Site conditions and wiring
The site uses a permanent magnet synchronous gearless traction machine. The encoder is a Heidenhain ERN1387 sine and cosine encoder with a resolution of 2048 lines. The encoder signal is fed back to the HD5L encoder interface. The HD5L receives the sine and cosine signals from the encoder for speed control, and at the same time outputs pulse signals with arbitrary integer frequency division from 1 to 128 to the controller for position control and speed monitoring.
The HD5L adopts a multi-speed terminal operation mode. The wiring diagram is as follows:
3.2 Parameter Settings
Set the basic parameters according to the operating mode and on-site wiring. The no-weighing parameters for group F6 need to be adjusted during subsequent no-weighing effect debugging.
Functional parameters | Setting values and descriptions | Functional parameters | Setting values and descriptions |
F00.05 Operation Method | 2 (Terminal Multi-Speed) | F06.00 Starting Pre-torque | 4 (No weighing compensation) |
F03.00 acceleration | 0.800m/ s² | F08.00 Speed Ring Ratio KP1 | 1000 |
F03.00 Initial acceleration | 0.350m/s 3 | F08.00 Speed Ring Ratio KI1 | 1000 |
F03.02 Ending segment rapid acceleration | 0.750m/s 3 | F08.00 Speed Ring Ratio KP2 | 1000 |
F03.03 Deceleration | 0.700m/ s² | F08.00 Speed Ring Ratio KI2 | 1000 |
F03.04 Initial rapid deceleration | 0.450m/s 3 | F12.01 DI1 function | 1 (Enable) |
F03.05 Rapid deceleration at the end of the segment | 0.450m/s 3 | F12.01 DI2 function | 2 (Upward) |
F05.03 Multi-speed 2 | 0.073 m/s (crawling speed) | F12.01 DI3 function | 3 (Downward) |
F05.04 Multi-speed 3 | 0.250 m/s (maintenance speed) | F12.01 DI4 function | 4 (Multi-speed 1) |
F05.05 Multi-speed 4 | 0.840 m/s (single-layer velocity) | F12.01 DI5 function | 5 (Multi-speed 2) |
F05.06 Multi-speed 5 | 1.320 m/s (double-layer velocity) | F12.01 DI6 function | 6 (Multi-speed 3) |
F05.07 Multi-speed 6 | 1.800 m/s (multi-level velocity) | F12.15 Y1 Function | 14 (Drive controller failure) |
F12.16 Y2 function | 2 (Drive controller is running) |
3.3 Debugging Steps
(1) When the synchronous traction machine is stationary and self-tuning, F10.10 is set to 1. Press the Enter key on the keyboard. The drive controller starts the motor parameter stationary self-tuning. The drive controller sends out pulse voltage. The motor will produce a humming sound. After the humming sound ends, the terminal gives the running direction command. After the traction machine runs at low speed for one cycle, HD5L identifies the motor magnetic pole angle and related information of the sine and cosine encoder.
(2) During maintenance operation, the controller is switched to the maintenance position, and the elevator operates normally when the elevator moves up and down during maintenance.
(3) When the command to run on the normal floor is given, the elevator runs normally.
(4) No weighing effect during debugging.
When debugging the no-weighing start-up effect, the main parameters to adjust are F6.14 (no-weighing current coefficient), F6.15 (no-weighing speed loop KP), and F6.16 (no-weighing speed loop KI). These three values should be increased as much as possible while ensuring the traction machine does not oscillate.
As can be seen from the current waveform in Figure 2, the current remains stable at zero speed during startup and shutdown. After startup, the current waveform is normal, and there is a short crawling phase during shutdown. The HD5L calculates a smooth S-curve acceleration and deceleration based on the target speed, and the acceleration and deceleration process is stable. This demonstrates the HD5L's excellent control effect on the traction machine and its smooth acceleration and deceleration curve.
As can be seen from Figure 3, the HD5L quickly adjusts to the torque to prevent the elevator from slipping the moment the brake is released. The current response is fast, with no overshoot and no oscillation.
4. Conclusion
The debugging results show that the HD5L elevator-specific drive controller effectively achieves smooth start-up of permanent magnet synchronous gearless traction machine elevators without weighing devices. Regardless of whether the elevator is running at high or low speed, or going up or down, the HD5L consistently controls the traction machine to operate smoothly, with excellent performance. The HD5L is poised to lead the trend in permanent magnet synchronous gearless traction machine elevators without weighing devices.
