Danfoss Drives

FOR THE FIBRE AND TEXTILE INDUSTRIES

Since Danfoss invented the first mass produced electronic frequency converter in 1968 and gave it the VLT name weve striven to set new standards for quality and performance in the category. In terms of quality, we consider it a professional challenge to earn every quality approval that matters, from ISO 9001 to CE certification. Our concern for quality and the environment is shared by everyone at Danfoss. Headquartered in Denmark, Danfoss is represented in more than 100 countries on six continents. What defines a quality drive? First, check the name if it says VLT, it says it all. Because there is only one VLT. The one Danfoss invented, and gave the name. Application know-how and strong dedication to research and development has brought us to the technological forefront with a broad range of products, specifically designed to precise customer needs.

Danfoss Drives
FOR THE FIBRE AND TEXTILE INDUSTRIES

VLT is a trademark of Danfoss A/S

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

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The Spinning Unit profits from the high output resolution ensuring an accurate pull of the fibres. Where more VLT drives are involved, interconnecting the DC links may solve the problems caused by mains dropouts.

The Extruder runs with a high starting torque and high speed accuracy, ensuring smooth and trouble free operation. For pressure control the integrated PID controller of the VLT drive keeps the pressure constant.

MAN MADE FIBRES AND FILAMENTS

The Stretching and Texturizing Unit benefits from the high accuracy of the VLT drive, which optimizes the process. The result is better product quality and less breaks, resulting in less costly downtime.

The Dryer operation is optimized, saving up to 30-50 percent of the energy consumption. This is achieved by the VLT drive controlling the fan speed, instead of adjusting the hot air flow with a damper.

The Cutting Unit mounted with a VLT drive is running with greater accuracy, ensuring that the filaments are cut to exactly the length prescribed.

The Baling Press process speed may be significantly increased with a VLT drive to synchronize the movements of the compression.

The Winder gets a higher winding speed, a better filling of the bobbin and thus a better quality of the fibre packages all thanks to a specially developed wobble software, integrated in the VLT drive.

or more than 20 years Danfoss has been a partner to the fibre and textile industries, supplying a vital technology safe, reliable and accurate frequency converters for AC motors. This cooperation has given us a working knowledge about the technological needs of the industry. All along we have transformed our know-how and insights into still better products, characterized by benefits like: Energy savings High reliability Low downtime Low cost of ownership A global service and support organisation with years of experience.

Integrated wobble option The VLT drive achieves the wobble function by changing the output frequency either according to a fixed pattern or at random. This makes any type of winding pattern obtainable, and the winder control system may be greatly simplified. Furthermore installation costs are reduced by avoiding a separate wobble generator. The integrated wobble option also handles elastic fibres. Fieldbus Communication is the ultimate answer to

process control and monitoring. By means of the fieldbus all stages of the process may be optimized. The VLT drive supports a number of fieldbus protocols such as PROFIBUS, LonWorks, Modbus+, DeviceNet, Interbus-S and others, which makes full integration into the control system an easy task. Load sharing Whenever a motor is being pulled by an overhauling load such as when the motor speed is being rapidly reduced, energy from the load is fed back to

the motor which then acts like a generator. This surplus energy is in turn fed back to the AC drive which may absorb it by means of a brake resistor, converting the energy into heat. In this way the energy is wasted. With the load sharing feature the surplus energy can be harnessed by interconnecting the DC rails of more drives into a system. In this way the energy is conducted to the other drives where it may be utilized. External control power supply Keeping the control system

alive during a power blackout or brownout is the overriding concern of a great many end users of textile machines. The VLT drive has an option which allows connection of an external 24 V d.c. power supply to keep its control section powered during a mains loss. This allows continous operation of monitoring systems, fieldbus communication, encoders etc.

SPINNING OF NATURAL AND MAN MADE STAPLE FIBRES

Bale Opener and Mixer With a VLT drive installed on the feed motor it becomes easier to control the quantity of the material conveyed and the process can run continuosly. Correspondingly the mixer capacity can be controlled. The whole process can be adjusted to match the capacity of the carding machines. Cleaner and Feeder A VLT drive adjusts the speed of the cleaner according to the mixer, thus optimising the process, ensuring better product quality and causing less wear. For the feeder drive, control means optimum conveying of fibres to the carding machine, contributing to better product quality. Carding Machine A VLT drive brings flexibility to the carding process: The mechanical gear is replaced by electronic control, making it quick and easy to change over from one type of fibre to another. With the incorporation of the SyncPos option all necessary functions can be achieved within the VLT. I addition, the kinetic backup feature protects the sliver against breaks during short power failures. Speed Frame With VLT drives you can implement your own optimised speed profile, resulting in a better bobbin build-up and allowing the process to run at maximum speed. Experience shows that typically a 10% increase in production is achieved and the automatic flyer positioning sequence means there is no need for the time consuming manual inching during doffing. Open End Rotor Frame A motor on each shaft, controlled by a VLT drive, replaces the mechanical gear. The benefits are less wear, minimum maintenance and notable energy savings. The latter becomes very significant on the bottom line, as an open end rotor frame is responsible for the lions share of power in an open end spinning mill. Ring Frame The 0.95 power factor due to the built-in DC link chokes makes further power factor correction superfluous, saving capacitors and maintenance. Low harmonic distortion is increasingly important as the number of drives in each mill is increasing in order to reduce the load of the mains. Last but not least considerable energy savings can be achieved - extremely important for the ring frame as the major power consumer of the mill.

Air Conditioner and Humidifier The speed of fans and water pumps in the a.c. system is controlled by VLT drives instead of being throttled by dampers and valves. This brings about energy savings of typically around 30 percent. At the same time better control of the relative humidity and temperature is achieved improving the product quality.
Ring frame Other machinery Humidifier Speed frame

pinning of staple yarns is a key process for the fibre and textile industries. The efficiency of this process is decisive for the profitability of your business. That is why you should choose Danfoss as your partner for AC drives. Our VLT frequency converters are specially designed to give you: Higher product quality due to gentle handling of the raw material. High operational reliability due to robust design and built-in EMC filters. Less downtime due to stable and smooth motor operation. Add to this energy savings that can cut your power expenditure by 10-20 percent. A reliability that brings new life to the phrase set and forget. Then you have the most favourable AC motor drives offered to the industry today.

Cleaning and carding

Typical energy consumption distribution in ring spinning mill Energy costs account for a substantial proportion of the manufacturing costs in the fibre and textile industries. The potential for savings is often underestimated and generally deserves more attention not least the ring spinning process. VLT frequency converters are a vital part of the efforts to reduce energy consumption. By meticulously metering the load-dependent energy supply to the motor they greatly reduce the amount of energy used in the many processes from feeder to air conditioning system.

Kinetic Backup A safety function to ensure undisturbed operation in spite of minor power failures: The mechanical energy of the motor is transformed into electrical energy, thus forming an emergency generator that keeps the drive powered until the mains supply is restored. The function is ideal for the fibre and textile industries, where it reduces the number of breaks all through the manufacturing process substantiully. Synchronizing and Positioning Option Synchronizing different

processes, positioning items or markers, programming several speed curves, setting infinite gear ratios, programming a number of sequences. Possibilities are numerous with the VLT SyncPos option. The performance of SyncPos could make the PLC obsolete, or make its job a lot easier. The on-board computer makes the option card a high performance, high speed and high resolution extension of the drive, turning it into an intelligent stand-alone control system.

Automatic Motor Adaptation (AMA) Thanks to AMA the VLT drive handles most motor adjustments itself. AMA works by automatically adjusting the drive to whatever motor you use, without the need to spin the motor or disengage the system. This makes the drive very user friendly and at the same time ensure optimum motor performance. Automatic Energy Optimizer (AEO) Applying VLT drives to the processes of the textile industry will very often mean a considerable energy

saving in itself. The recent generations of the drive, however, have added an intelligent feature that provides even further savings: The AEO function automatically monitors the power requirement of the application and reduces the power output to match the actual need. VLT software dialog A software tool is available to up/download settings and read all operational data. It communicates with all drives in a network and makes commissioning a lot easier.

WEAVING AND KNITTING

TEXTILE TREATMENT AND FINISHING

Circular knitting machine Equipped with AC motors and VLT drives the machine is is not affected by the dusty production atmosphere thanks to the IP 54 enclosure rating. Typically this compares to an IP 20 rating associated with DC motors and drives making the latter vulnerable and maintenance-demanding in the fibre and textile industries. Furthermore AC motors are available as a standard,which adds attractive initial costs to the lower running costs. On top of this the better system efficiency of AC solutions offers considerable energy savings.

Winding and Unwinding A VLT drive provides exactly the right winding tension, so that the web is wound uniformly onto the cylinder. The web tension is usually measured by a dancer with a position sensor, acting as feedback to the integrated PID controller.

Printing The accuracy of a printing process is greatly improved with a VLT drive. Mounted with the SyncPos option, the drive coordinates the position of the material and the printing unit, with extremely precise results. The versatile SyncPos option can be tailor-made to suit numerous applications and any programming is done with user friendly Windows based PC software.

Looms VLT drives increase the production of the looms as the speed can be optimized for the actual product. Another advantage of the Danfoss drives over mains operation is the ability to compensate for an insufficient power supply, that makes the looms run slower. The VLT drives maintain a steady motor speed by means of a precise slip compensation and they are able to compensate for variations in mains voltage as well as mains frequency.

ust and fluff in the air is a steady follower in all textile industries not least when it comes to weaving and knitting. Here a hairy atmosphere often means frequent maintenance of motors and drives and in worst case causes downtime. This is a good reason for choosing AC motors and matching VLT drives from Danfoss. Their optional dust tight IP 54 enclosure make them practically maintenance free and thus less expensive in running costs. Space saving is a much asked quality in weaving and knitting applications. With a newly released combined drive and motor integrating motor and a frequency converter Danfoss offers the most compact and efficient solution in this field to date.

Poor Supply Compensation In many textile producing countries the power supply is very unstable with fluctuating mains voltage and frequency. With mains driven motors insufficient voltage may cause motor overheating. Insufficient mains frequency (e.g. 48 Hz instead of 50 Hz) lowers the actual rpm by 4 percent a loss that is never regained: It makes the machinery 4 percent slower. A VLT drive compensates both, so that nominal voltage and frequency is supplied uninterruptedly. Mains voltages as low as 15% below nominal can be compensated for.

Motor and Drive in One The VLT DriveMotor is an integrated energy saving motor and frequency converter, no larger than a standard motor with terminal box. It not only saves panel space but also removes the needs for expensive shielded cabling. The drive motor also comes with a built-in PID controller and the ability to be mounted in any position and direction. It is protected against thermal overload, missing phase, undervoltage and voltage transients all in all meeting the needs of many textile applications.

lso the last phases of the textile production process require reliability, accuracy and preferably a cost competitive technology. All these demands can be met by installing VLT drives in vital functions, whether it be a winder, a washer/dryer, a dyer, a textile printing machine or a cutter. Textile treatment and finishing applications often consist of complex systems with a large number of drives involved. The wiring and installation costs are greatly reduced by using fieldbus communication. At the same time it allows all drive parameters to be monitored an important process optimisation tool.

Torque Control controls the torque of the motor shaft with similar performance to a DC drive/motor system, but with better profitability thanks to lower initial and running costs. By allowing for the frictional losses in the system the torque is linear throughout the entire speed range. High Starting Torque The VLT drive has a very high starting torque, yielding a breakaway torque of 180 percent. This enables the drive to even start up heavy and slow machines with a high degree of inertia and friction. High Impact Load This function makes the motor

immune to shock loads, thus ensuring a constant speed, even with varying loads. No derating Thanks to the patented VVC and VVCplus control principle operation with VLTdrives results in the same motor conditions as with mains operation. No extra heat is generated and it is unnecessary to buy bigger motors than prescribed. Integrated filters VLT drives come with integrated RFI filters. The filters offer maximum Electro Magnetic Compatibility (EMC) in noisy environments, and they are built into the devices, avoiding installation of external filters.