Shangchai reviews the quality management system of Rheinland
Preface
The B1012 single-arm shaper has been in use for over three decades. Its worktable transmission system originally relied on a DC motor-generator set, which was known for its high failure rate and significant energy consumption. To address these issues, an inverter-controlled motor system was introduced. This modern solution offers substantial energy savings, easy speed adjustment, and simplified maintenance, making it an ideal upgrade for this aging machine tool.
1 Overview of the B1012A Single-Arm Shaper Before the Upgrade
The main components of the single-arm shaper include the bed, table, column, beam, worktable drive system, feed box, lubrication system, hydraulic safety device, and electrical equipment. The worktable drive system used a combination of a DC generator set and a second gear to perform deceleration, reversal, and slow cutting operations—this was considered the main drive system. Meanwhile, the clamping and lifting of the beam, as well as the movement and rotation of the tool holder, were part of the auxiliary drive system. The automatic cycle control for the worktable movement was achieved using a combined proximity switch.
2 Control Requirements for the Single-Arm Shaper
a. Smooth operation with stepless speed regulation across a wide range.
b. Ability to adjust working speed according to different workpieces, with independent forward and backward speed control.
c. Excellent starting and braking performance.
d. A simple, safe, and reliable system that is easy to maintain, low in noise, efficient, and energy-efficient.
3 Main Drive System Upgrade for the Worktable
3.1 Selection of Motor, Inverter, and External Components
The main drive system now uses a Y225M-6 37 kW asynchronous motor, paired with a FRN45G11S-4CX inverter from Fuji Electric. Given the specific operating conditions of the single-arm shaper, the selected inverter was one size larger than the motor’s specification to ensure stability. During rapid deceleration and braking, the motor generates significant feedback energy, so the planer’s reversing brake incorporates both deceleration braking and an external braking resistor unit. This allows the excess energy to be dissipated through resistance heating, improving braking efficiency and reducing wear on the system.
3.2 External Wiring Diagram of the Inverter (see the figure below)
3.3 Inverter Function Parameter Adjustment
To ensure the inverter meets the load and operational requirements, several key parameters must be configured:
3.3.1 Frequency Setting – F01 is the frequency setting function. During commissioning, you can choose 0 for keypad adjustment or 1 for voltage input via terminal [12] (0–10 V). The frequency can be set based on the required operating speed.
3.3.2 Operation Command – F02 controls the running command. It is set to 1, allowing external terminals [FWD] and [REV] to control the motor's direction.
3.3.3 Acceleration/Deceleration Time – F07 (acceleration time) and F08 (deceleration time) are both set to 1.8 seconds, depending on actual performance.
3.3.4 Torque Boost – F09 is set to approximately 10 to provide constant torque characteristics, especially at low speeds. However, increased torque boost may cause overexcitation at low speeds, potentially leading to overheating if operated continuously. Motor characteristics should be checked accordingly.
3.3.5 Frequency Limitation – F15 sets the upper frequency limit to 50 Hz, suitable for universal motor applications.
3.3.6 Motor Parameter Settings – P01 is set to 6 poles, P02 to 37 kW, P03 to 71 A, and P04 to 2 (motor self-tuning mode, requiring no load during setup).
4 Conclusion
After replacing the original DC motor-generator set with an inverter-based system, the B1012A single-arm shaper now operates smoothly and efficiently. The transformation has met all production process requirements, significantly reduced energy consumption, improved productivity, and made adjustments and maintenance much easier. The results have been highly satisfactory and demonstrate the effectiveness of modernizing older industrial equipment.
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