Winding Machine Spindle Inverter Overvoltage Alarm

The main shaft inverter of the automatic winding machine produces an oL overvoltage alarm on the operation panel each time it stops. Measuring the input side power voltage with a multimeter revealed it to be normal, thus pinpointing the issue to the deceleration time setting in the inverter. To minimize the moment of inertia during the main shaft stop, the inverter's deceleration time is set to be very short, resulting in a sharp drop in frequency after the stop signal. Consequently, the synchronous speed of the motor is extremely low but fast, as the winding motor with high inertia actually exceeds the synchronous speed. When the winding motor operates in the generator state, it causes the inverter to generate an overvoltage alarm. Through actual debugging, the system's deceleration time is set to 0.5 seconds, which can significantly reduce the inertia of the winding machine during deceleration, ensuring no overvoltage alarms occur.

2. Winding Machine Servo Drive Alarm Handling

During the debugging process, the active cable servo driver of the winding robot frequently displayed fault alarms. The usual cause is abnormal communication between the encoder and the servo driver. After disconnecting the power to the servo driver, reconnect the connector CN2 between the encoder and the servo driver. Upon re-powering, the fault was eliminated.

3. Setting the Servo Capability of Winding Machine Cable

By adjusting the parameters of the servo drive, the cable's servo-following capability is achieved. The higher the parameter value, the smaller the execution error of the directional commands, and the stronger the following capability; however, this value is considered too high. The active winding machine is prone to vibration, so the setting of this parameter should consider the winding machine itself and the tracking of directional commands.

4. Identification of the winding machine's winding sampling cycle

During the debugging process, it was discovered that the winding arrangement of the winding machine exhibits a noticeable step-by-step pattern. Within each pause cycle, the travel time is short, while the stop time is long, resulting in inconsistent tension. Consider reducing the sampling cycle to twice the PLC scan cycle and continue debugging. It was found that the cable arrangement can smoothly move without stopping, and the cable is tighter.

5. Tension during winding

The tension of round wire during winding is adjusted by the number of wraps on the松弛辊. When winding finer round wire, improper tension adjustment can lead to elongation and insulation of the fine wire. In cases of paint peeling, manufacturers should determine the appropriate number of wraps for different round wire diameters.

6. Tension during winding

The tension adjustment for the winding machine during the winding of flat wire is achieved by adjusting the air pressure of the disc brake pad. We should also summarize the corresponding air pressure for different wire widths.