Synchronous Motor Wire Drawing Machine
Synchronous motor wire drawing machine is a new type of wire drawing machine independently researched and developed by our company to meet the market demand and has full intellectual property rights.
It features high efficiency, high precision, and fast response. and represents an upgraded and advanced version of traditional AC motor-based wire drawing machines.
At present, there are two models of rough drawing and fine drawing, which are recognized and highly praised by customers for their simple and compact structure, high operating efficiency, energy conservation and other advantages.
The rough drawing process is to draw Φ5.5mm base metal into Φ2.4mm wire, and the fine drawing process is to draw Φ2.4mm wire into Φ1.6mm, Φ1.2mm, Φ1.0mm, Φ0.8mm wire.
Product Details
Advantages of Synchronous Motor Wire Drawing Machine
Simple and Compact Structure.
The motor drives the drum directly, so that there is no need for reduction gearbox and belt reducer.
The working efficiency is enhanced and the work required for maintenance is reduced, such as adding the lubricating oil into gearbox, change the belt and so on.
More Efficient
The rotor speed of the synchronous motor is completely synchronized with the stator magnetic field, and no slip difference between the stator and rotor is needed to generate torque to drive the load.
Compare with asynchronous motor, there is no rotor eddy current loss.
Furthermore, since these motors do not adopt fan cooling, windage and friction losses are further reduced, resulting in an efficiency improvement of 2% to 8% compared with asynchronous motors.
Motor directly drive the load, which reduces the energy loss between intermediate transmission devices leading to a higher transmission efficiency.
Synchronous motor can maintain a high power and electric conversion efficiency within the range of 25%-120% of rated load.
In contrast, for asynchronous motors, the conversion efficiency only approaches its maximum value when the load and rotational speed are close to the rated values.
The further the operating condition deviates from the rated load and rated rotational speed, the lower the conversion efficiency becomes.
High Power Factor
Because the rotor is made of a permanent magnet, the stator side of the permanent magnet synchronous motor does not need to provide excitation current, and the power factor is relatively high and maintained in the whole power range, up to 0.99 or more.
Therefore, the reactive power saving effect of permanent magnet synchronous motor is remarkable.
Large Starting Torque, Strong Overload capacity, and suitable for Multiple pairs of magnetic poles
The rated speed of synchronous motor can be set as tens of RPM to meet the requirements of low speed and large torque of the wire drawing machine.
Power Saving
Due to the above characteristics of synchronous motor wire drawing machine, combined with the actual production condition, compared with traditional asynchronous motor wire drawing machine, the power energy can be saved up to 10-15%.
This comparison is made between the wire drawing machine that produced from our company, if the comparison object is different, the energy saving effect will be different.
Following are the practical production data from our customers:
When TBWL560/6 rough wire drawing machine drawing the welding wire made of ER50-6：inlet:Φ5.5mm、outlet:Φ2.4mm，speed:10m/s，800 take-up machine power:18.5KW.
The power consumption is about 80kW.h/ton, excluding the power consumption from the pre-treatment equipment.
When TBWL400/6 fine wire drawing machine drawing ER50-6; Inlet: Φ2.5mm, outlet: Φ1.25mm，speed: 20m/s, the practical power consumption is 90kW.h/ton.
Better Motor Protection Measures
The stator windings and spindle bearings of motor are equipped with temperature sensors to detect real-time temperature.
When the temperature goes too high it will be detected immediately.
Less Noise
The synchronous motor drives the drum directly, so there is no noise from intermediate transmission devices such as reduction gearbox or reducer belt.
Advantages of Our Synchronous Motor
Does not rely on any external cooling steps
The current density designed by our company is relatively small, so the motor generates less heat.
The natural heat dissipation of the motor is enough to cooling the motor to the desired temperature.
Therefore, our motor does not require any external or additional heat dissipation such as fan cooling, motor water cooling, etc.
Although the motor cost is greatly increased due to the large volume of the motor, the user can completely avoid the motor malfunction caused by external heat dissipation and reduce the use cost accordingly.
The motor has no encoder, avoiding malfunction
Our synchronous motor has special designs.
When starting, our synchronous can rely on the high-frequency current of the frequency converter to identify the position of the magnetic pole, and it can achieve a larger torque in the low-speed section of the starting time.
For common synchronous motors, if there is no encoder, the frequency converter cannot identify the rotor position and cannot operate normally, so an encoder must be installed on the motor shaft.
No encoder design avoids encoder failure caused by the shutdown, reduces equipment failure, and increases the stability of the operation of the drawing machine.
The electric control cabinet can be placed next to the wire drawing machine or centrally placed in the far power distribution room
The signal line generated by the encoder is susceptible to electromagnetic signal interference in the industrial site.
For example, frequency converters and switching power supplies, as well as inverter welding machines and etc., can generate electromagnetic radiation signals or cause harmonic interference to other equipment through the AC power line.
The longer the signal line, the greater the chance of interference.
If the synchronous motor is equipped with an encoder, a relative far distance between the motor and the controller could cause the encoder signal to be interfered.
Therefore, the electric control cabinet has to be placed near the wire drawing machine (motor) to reduce interference.
The synchronous motor of our company, because there is no encoder installed, can be placed in a far location, which is convenient for users to centrally place and manage the electric control cabinet.
The electric control cabinet is placed near the wire drawing machine, which requires higher requirements for dustproof and cooling.
Machine Types
Rough Wire Drawing Machine
The rough drawing process is to draw Φ5.5mm/ Φ6.5mm base metal into Φ2.4mm wire.
Generally diameter of capstan is Φ560mm.
Fine Wire Drawing Machine
The rough drawing process is to draw Φ2.4mm base metal into Φ1.6mm, Φ1.2mm, Φ1.0mm, Φ0.8mm.
Generally diameter of capstan is Φ480mm.
