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Effective protection of machine tool equipment
An important electrical parameter of machine tool is the effective power of motor. Using Phoenix Contact's contactron motor manager, this parameter can be accurately monitored, and high overload and low load operation can be detected by this instrument immediately. Because the motor manager can send out alarm and maintenance prompt in time before the motor breaks down, it can effectively protect the machine tools and improve the usability of the machine tools.
In industrial applications, motors are generally used to start production. In general, it is protected by the motor current protector which plays a protective role according to the length of the over-current time, or by the motor protection switch for overload protection according to the load size. However, when the cooling fan of the motor reverses, or the cooler is blocked and cannot achieve normal cooling, what happens to the motor?
FDT / DTM software for parameter assignment, fault diagnosis and production data acquisition
Current monitoring is often inadequate
There is no doubt: when the temperature of the motor rises to a certain critical value, it will lead to the failure and damage of the motor. As a solution, a thermistor can be installed in the winding of the motor and connected with a control switch which can cut off the motor current when the motor temperature is too high. It is composed of a temperature control switch and a temperature sensitive switch. However, this protection scheme has little protection effect on the follow-up mechanical equipment or mechanical structure, which can not avoid their failure under the worst working conditions.
The main reason of motor failure is that many users reserve too few motor variants in order to reduce inventory. In practice, about 90% of the working load of the motor is only 40% - 60% of the rated power, which is not in the range of its optimal operating characteristics. The over-current protection device of these motors is set according to the rated power on the motor name plate, and is set according to the parameters of the motor in the best working characteristic range. When the load changes, even a small change will be reflected in the power factor and efficiency; the change of motor current almost remains unchanged. However, the mechanical device may still be overloaded, and no problem will be displayed in the pure current monitoring system. This will bring serious consequences to the machine tool equipment: the mechanical device driven by the motor is seriously damaged and expensive.
Detection of effective power to improve the protection of machine tool equipment
According to this monitoring method, alarm information can be sent out quickly, or the power supply of machine tools can be cut off. The detected data, which can draw the motor running curve, truly reflect the working condition of the machine tool and clearly show the difference between the theoretical observation data and the theoretical calculation data. With this contactron motor manager, the effective power of all machine tool equipment components and instruments installed behind the motor, such as bearings, mechanical parts, etc., can be taken into account and displayed together, and safety protection can be given quickly (Fig. 2). Compared with the pure current protection, the monitoring based on the effective power can also play a role of safety protection under low load, such as the oil loss operation of the pump, etc. it can complete the tasks that need auxiliary use of the effective power monitor for a long time.
The saved start-up operation curve is an important data of equipment operation status, because it can be used as reference data for equipment aging, dirt degree or wear condition. Using this curve, all the monitoring parameters, the upper and lower limit values of monitoring, and the corresponding alarm, prompt or cut-off power supply, parameter assignment and other information corresponding to these limit values can be accurately determined. The parameter assignment of the manager is carried out by using DTM (device type manager) software, which can be compatible with FDT (field device tool), such as automation Xplorer of Phoenix Contact company. In this way, the motor manager can be integrated into various engineering tools or control systems.
Only the effective power is allowed to monitor the whole range of the upper and lower limit load of the machine tool. As the protection switch of machine tool equipment, it ensures the high availability of machine tool equipment, and also ensures the high production capacity. By using its effective power monitoring function, it can find out the fault and interference in the process of use in time, so as to avoid the equipment shutdown fault. As the basis of technical data calculation, it is based on electrical data: electrical data obtained by using motor as sensor. Time consuming and laborious additional sensors, even expensive sensors, such as pressure sensor, flow sensor or differential pressure sensor, can be omitted. Other electrical parameters, such as working time of different gears, total working time of machine tools and energy used, can be collected while optimizing maintenance.
It is easy and convenient to use the power supply cable of the motor to make up
The motor manager with integrated current converter can directly monitor the motor with 16A current, and the installation can be completed without occupying too much space. When the current of the motor is larger, a special module can be used, combined with the external current converter, the motor of various power levels can be monitored. Therefore, it is very simple to use this instrument to monitor the motor and machine tool equipment: only the cable that supplies power to the motor is used. In this way, it is possible to add this kind of motor manager to the existing equipment, and can provide accurate operation data for users in the future.
The cut-off of three-phase electrical load is completed by special mechanical relay or semiconductor relay which is wear-free and uses digital output of motor manager module to supply power and power off. At this time, the motor manager provides the safety monitoring and protection of the pump, console or cutting machine tool, and evaluates the power energy required by each equipment. In this monitoring process, no matter whether the motor manager is powered by itself or by using fieldbus, it can complete this task well.