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Industrial processing section in Low-E glass vacuum coating production line mostly uses servo drive transmission control system. The servo transmission system, with its high precision and fast response, has always been the preferred transmission method for vacuum industrial processing section in this industry. In actual production, the servo transmission system has four problems that affect its reliability: 1) Due to free cooling, when in high temperature season, the servo motor running in high temperature, which makes it high failure rate and unreliable; 2) It needs specialized driver module, servo drive and servo motor, with poor compatibility; 3) It needs specialized cable (not longer than 30m) between the servo driver and motor, and the driver should be installed near the motor on site, however, there are many interference on site, such as the intermediate frequency power supply, DC power supply, vacuum pump, pure water pipe; 4) Many devices, and most of them are specialized devices, making the system very expensive,
In 2007, the Low-E glass vacuum coating line project for Zhejiang Dongya Project Glass CO.,LTD, which I was responsible for design, programming and debugging, adopts AC variable frequency transmission system. Integrated with the requirement of vacuum coating line transmission system, this AC variable frequency transmission system uses Reliance Electric RPM AC variable frequency motor and Allen-Bradley PowerFlex 700 series project vector AC inverter. Reliance RPM AC motor is configured with forced cooling, 1024 PPR encoder feedback, speed range is 1000:1, speed regulation range is ±0.1rpm. Powerflex 700 is equipped with encoder interface module and Contronet communication module, speed regulation range under full vector control is 1000:1, speed regulation range is ±0.1rpm, with Force magnetic flux control technology, with brake resistor.

   Variable frequency transmission system uses inertia compensation to solve the synchronization problem among acceleration and deceleration process, speed and torque, and uses torque leading compensation control algorithm to solve the problem of large adjustment range of speed loop and slow response due to load size changes when glass in chamber synchronized transmission process. It makes use of Reliance RPM AC variable frequency motor’s features and synchronization control algorithm to avoid the potential malfunction due to inverter’s frequent start and stop in normal production.

   Through actual production, the variable frequency transmission system’s actual technical parameters as follows:
1)The longest cable between inverter and motor is 150 meter.
2)deceleration distance<150mm
3)stop distance <10mm
4)speed regulation range: 1000:1(0~45米/分)
5)line speed accuracy <0.001 m / min
6)speed synchro-speed error <0.1rpm
7)When sputtering speed is 5m/min, pot distance <200mm
8)When weather temperature is 42 Celsius degree, the motor temperature <50 Celsius degree.

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