Machine tools is an important parameter is the motor electrical effective power. Using Phoenix Contact's Contactron motor manager, this parameter can monitor the precise, high overload and low load operating conditions can be immediately detected by this instrument. As motor manager fails to stop the motor before the alarm time and maintenance tips, which can effectively play a protective effect on machine tool equipment, so that significantly improved the availability of machine tools.
In industrial applications, generally with a motor to start production. Under normal circumstances, it is by the length of time in accordance with the overcurrent protective role of the motor current protection to protect; or by the size of the load motor overload protection switch. However, when the cooling fan motor reversal, or cooler plug, the normal cooling can not be achieved, how will the motor?
There is no doubt: when the motor temperature rises to a certain critical value, failure will lead to motor damage. As a workaround, you can install a motor winding thermistor and the thermistor temperature is too high and that the motor cut off the motor current when the control switch connected together. Both thermistor and temperature control switches constitute the full protection of the motor. However, this protection scheme for its follow-up of machinery or mechanical structures had little protective effect, can not prevent them from working in the worst cases, is still there failures.
Motor failure is mainly due to: many users to reduce inventory, reserve too few varieties of motor variant. In practice, approximately 90% of the work load of the motor rated power is only reached 40% to 60%, not the best operating characteristics in the context of its work. These motor overcurrent protection device is in accordance with the motor nameplate rated power set is the best operating characteristics in accordance with the motor parameters within the set. When the load change, even small changes, but also in power factor and efficiency reflected; changes in motor current is almost unchanged. Nevertheless, the mechanical device may still be overloaded, while the net current monitoring system, but does not display the problem. This will have serious consequences for machine tool equipment: motor-driven mechanical device severely damaged expensive.
Detection of effective power to improve the protection of machine tool equipment
Phoenix Contact R & D production Contactron series motor Manager with effective power collector, you can protect the motor and machine tool equipment. Since the entire power range of the motor, only changes the effective power is linear, so you can keep informed of such a linear size of the motor output torque. On the other hand, only in the over-current and low-load power factor of these two parameters to protect the motor. Motor Manager parameters for all the variables to monitor, such as: current, voltage and power factor; and 6.6ms after the detection of the data according to calculated effective power, and thus able to determine that the load time is very short change.
According to this monitoring method that can quickly send alarm information, or to cut off the power supply machine tool equipment. Detected, you can draw the curve of the motor to run the data, a true reflection of the working conditions of machine tool equipment; clearly shows the observational data and theoretical calculation, or the difference between the data. Using this Contactron motor Manager, all installed in the machine tool after the motor parts and equipment, such as bearings, mechanical components such as the effective power can be taken into account together and displayed, and can quickly provide security protection (Figure 2 .) And compared to the pure-current protection, based on effective power monitoring can play in the low load the role of security, such as loss of oil pump operation, etc., to complete a long time supporting the use of effective power needed to complete the task monitor.
Preserved up and running curves are important information equipment operation, as can be used as aging equipment, dirt or wear of the degree of reference materials used. Using this curve, you can accurately identify all of the monitoring parameters, monitoring of the upper and lower limits and the limits corresponding to these alarms, prompts, or cut off the power supply, parameter assignment and other information. The manager of the parameters of the assignment is to use DTM (Device Type Manager) software, the manager can use this motor with the FDT (Field Device Tool), such as Phoenix Contact's automation management software AutomationXplorer compatible. In this way, motor manager can unified, stable integration into a variety of engineering tools or control systems.
Only the effective power of the machine tool equipment to allow the upper and lower limits to monitor the entire range of load. As the machine tool equipment protection switch, which ensures high availability machine equipment, which also guarantee a high production capacity. Use of its effective power monitoring capabilities to enable it to detect the fault during use and interference in order to avoid equipment downtime. Technical data as the basis for calculation, is based on electrical data: the use of electric motors are also offering electrical sensor data. Time and effort of additional sensors, or even expensive sensors, such as pressure sensors, flow sensors or pressure sensors and so can be omitted. Other electrical parameters, such as the working hours of different stalls, the total working time machine equipment and the use of energy, can be optimized while maintenance is collected.
Use of motor power supply cables to make installation easy and convenient
Current converter using an integrated motor managers can directly monitor the motor current is 16A, without taking up too much space to complete the installation. When the motor current is greater, you can use a special module, combined with external current of each power converter will be able to monitor the level of the motor. Therefore, the use of this instrument is to monitor the motor and machine tool equipment becomes very simple: by using only the power cable to the motor. Thus, to supplement existing equipment, motor assembly manager that is possible in the future will also be able to provide users with precise machine tools to run data.
Three-phase power load cut off by a special series of mechanical relays or by Contactron no wear and use of motor management module digital output side power supply, power control semiconductor relay to complete. At this point, motor manager provides a pump, cutting machine console or safety monitoring and protection, and electrical energy required for each device were assessed. In this monitoring process, both are self-powered motor manager or use of fieldbus power supply, can better accomplish this task.
Phoenix Contact in research and development production, in line with DPV1 technical specifications (EN 50170) certified Profibus fieldbus gateway help, can be a maximum of 32 simple motor management module installed in the connector card slot on the T-Bus can achieve the communication between each other (Figure 3), no complicated wiring. Common on the market compared to other solutions, this program can significantly reduce investment costs, saving installation space in the electrical cabinet. All production data are available through the FDT / DTM transfer to the upper level control system, higher level control system for processing. In addition, Profibus fieldbus gateway also supports failure - security: the parameters of the assignment by DTM Profibus field bus system can malfunction and errors in influence, the security of power control. In addition, such equipment also comes with digital I / O terminals, contact with other components. In Profibus DPV1 system for the gateway integration method described by GSD instrument assignment, using FDT / DTM in motor manager and assign the parameters of the machine tool equipment, monitoring and fault diagnosis greatly increased flexibility.
Phoenix Contact R & D production of motor cycle, according to the requirements of maintenance realize the 8 mode and power state transition; with the state of continuous monitoring and high sampling rate to ensure high availability of the machine tool equipment. In the motor power supply by simply connecting the cable on, so the motor has become a sensor, can provide a variety of useful electrical parameters, such as apparent power, reactive power and active power, current, voltage, power factor, switch time, work time and energy consumption. Expensive detectors, sensors are not necessary components of the installation.