Technology-driven, intelligent manufacturing upgrade: SANYU frequency converters achieve successful application and efficiency leap in metal wire production lines

Recently, a well-known domestic metal products company achieved remarkable results by fully adopting SANYU’s new generation of high-performance vector frequency converters during the intelligent transformation of its high-speed metal wire production line. The success of this project not only signifies the mature application of SANYU frequency converter technology in complex industrial scenarios but also provides a benchmark example for energy conservation, efficiency improvement, and intelligent upgrading in the metal wire processing industry.

Challenges: High-demand production lines and bottlenecks in traditional drives

This metal wire production line is mainly used to produce copper wire, steel wire, and other products of various specifications. Its process includes multiple precision steps such as unwinding, drawing, annealing, cooling, and winding. The original drive system used by the company faced numerous challenges:

1.Unstable tension control: During the unwinding and winding process, tension fluctuations cause scratches on the wire surface and frequent wire breaks, making it difficult to improve the product qualification rate.

2.Poor speed control accuracy: Poor speed coordination between multiple motors results in wires being either too loose or too tight, affecting production continuity.

3.High energy consumption: Traditional motors are inefficient under partial load conditions, resulting in a large waste of electrical energy.

4.High maintenance costs: The system has a high failure rate and frequent downtime for maintenance, which seriously affects production efficiency and delivery cycle.

Solution: The Precise Empowerment of SANYU Frequency Inverters

To address the aforementioned pain points, the technical team tailored a drive solution centered on the SANYU SY series vector frequency converter for the core equipment—the drawing machine, tension control roller, and precision winding machine.

1.Superior vector control technology: SANYU frequency converters provide high-precision torque control and speed regulation, ensuring speed synchronization throughout the entire process from drawing to winding, achieving constant tension, and fundamentally eliminating quality problems caused by unstable tension.

2.Smooth start-up and braking: The inverter’s built-in S-curve acceleration and deceleration function ensures smooth start-up and shutdown, avoids mechanical shock, effectively protects the motor and transmission mechanism, and extends the service life of the equipment.

3.Powerful adaptability: Faced with drastic load changes, SANYU frequency converters can quickly respond and automatically adjust their output, ensuring stable operation of the production line under various complex working conditions and significantly reducing the break-off rate.

4.Significant energy-saving effect: Through variable frequency speed control, the motor can intelligently adjust its speed according to actual load requirements, avoiding the phenomenon of “overpowered motor for underpowered loads”. Actual test data shows that the overall energy consumption of the production line has been reduced by more than 15%.

Application Results: Dual Improvement in Efficiency and Quality

Since the successful commissioning of the SANYU frequency converter, this metal wire production line has achieved comprehensive upgrades:

1.Product quality has improved significantly: the surface finish of the wires has been improved, the dimensional consistency is better, and the product qualification rate has increased by nearly 8%.

2.Production efficiency has increased dramatically: production line operating speed has increased by 20%, and unplanned downtime caused by line breaks and shutdowns has been reduced by 70%.

3.Operating costs are effectively reduced: In addition to significant energy savings, equipment maintenance costs and the frequency of consumable replacements also decrease.

4.Enhanced automation level: This lays a solid foundation for subsequent integration with the central control system and the realization of full-process digital monitoring and management.

Industry Outlook

The project leader stated, “Choosing SANYU frequency converters was a crucial step in our technological upgrade. Their stable performance, precise control, and outstanding energy-saving effects completely exceeded our expectations. This is not just an equipment replacement, but a revolution in our production model.”

Industry experts point out that the successful application of SANYU frequency converters in metal wire production lines fully demonstrates the strong capabilities of domestically produced high-end industrial control products in solving specific industry challenges. With the deepening of “Industry 4.0” and “Made in China 2025,” independent core technologies represented by SANYU are becoming a mainstay in driving the transformation of China’s traditional manufacturing industry towards intelligence and green manufacturing.

About SANYU:

SANYU is a renowned supplier of industrial automation control products, committed to providing global customers with efficient and reliable inverters, servo systems, PLCs , HMIs , and other products and solutions. The company consistently adheres to a technology-driven innovation strategy, helping customers across various industries achieve industrial upgrading and sustainable development.

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