CONTROL SYSTEM OF THE WIREDRAWING MACHINE

WITH ANNEALING MODULE

Vadim CAZAC, Ilie NUCA, Petru TODOS, Iurie NUCA
*

Technical University of Moldova
*
Technical University of Cluj-Napoca
vadimcazac@gmail.com, nuca_ilie@yahoo.com, todos@adm.utm.md, nuca.iurie@yahoo.com

Summary This paper is focused on developing unified
microprocessor control system of a wiredrawing machine
which integrates the modules of the following subsystems:
wiredrawing, winding and annealing of the metal wire. The
main aim of this work consists in elaborating a system of
better control for the wiredrawing and for the annealing
module, all this for elevating the productivity and the
quality of the technological process of making electrical
wires.
The reference object of this paper work is referred to a
machine of the B-24 type [7], which contains the
asynchronous motor with belts of the wiredrawing line
transmission, the controlled drive system of the drum
winding and the wire annealing module with manual
prescription of the necessary temperature (fig.1). Thus has
appeared the necessity of upgrading the automation system
of this wiredrawing machine according to the requirements
of the economical agent [8].
According to the technological process the developed
control system must control the necessary wiredrawing
force, speed and tension force prescribed to the wire, slow
start depending on the tension force, maintaining of a
constant tension force for excluding the breaking of the
wire at high speeds of winding, regulation of the energy
flux of the annealing module depending on the linear speed
of the wire.
The system ensures a gain of productivity and quality of
the technologic process of electric wires production. For
the winding mechanism a vector control system with three
contours of current and speed regulation, and one exterior
contour of the wires tension force. Through computer
simulation the control systems performance indices were
proven.

Keywords: drawing, annealing, control system, electric
drive, vector control.
1. INTRODUCTION
The main course in developing of wire and cable
production is implementation of new technologies,
which allow intensifying the technological process and
elevating the economical efficiency, as well as obtaining
products with wanted physical and mechanical
proprieties.
Wiredrawing is the main method of wire production and
consists of pulling the metal wires through dies [1-3] .
The wires obtained after the drawing have exact
geometrical measurements with wanted physical and
mechanical proprieties (elasticity, plasticity). Compared
to other methods wiredrawing excludes any losses of the
processed material.
Modern wiredrawing machines are completely
automated and integrate in a unique system the
equipments of the wiredrawing process as well as of the
annealing process [4-6]. Older wiredrawing machines
have less automation which leads to the decrease of the
productivity, or breaking of the wire.


2. STRUCTURE OF THE CONTROL SYSTEM
According to the imposed task a control system of the
drawing machine was developed, which consists of 3
subsystems: of the wiredrawing asynchronous motor
drive, of the winding motor drive and of the wire
annealing module (fig.2). The general control of the
system is entrusted to a programmable microcontroller
1, whose control parameters can be changed through the
operators panel 2. For feedback are used current
transducers 3, 4, 5; speed 6, wires tension force 7.
The mechanical connection between drawing and
winding mechanisms is made through the drawn wire.
Fig.1. General view of the wiredrawer B-24

1
2
6
5
7
12
11
10
8
3
9 4


2.1. The drive system of the wiredrawing machine
The wiredrawing process takes place at a speed of 50
m/s (averaging 20-25 m/s). The drawing force is
developed by the traction drums and the friction force
between the drum and the processed wire by it. It
depends, mostly, on the friction factor in the dies of the
machine.
The wiredrawers drive system must develop the
necessary speed to overcome the drawing force to the
prescribed speed. The system consists of: an
asynchronous motor 8, a frequency converter with
scalar control 9. The motor does not require a drive
with high dynamical parameters, thus it functions with
its natural characteristic, without feedback loops.
2.2. The drive system of the winding machine
The winding machines drive system maintains the
prescribed speed and tension force to avoid breaking
the wire. It contains an asynchronous motor 10 and a
vector control frequency converter 11.

2.3. The control system of the annealing module

Annealing is a way of thermal processing, which
consists of heating, maintain and sudden chilling a
plastic and soft, free of inner stress, metal is obtained.
The temperature for annealing can be higher or lower
than of the critical, at which the metal suffers inner
changes. The operating principle of this module is
based on the induction of a electromotor tension into
the drawn wire, which cause appearance of eddy
currents thus producing the necessary heat for the
annealing through the Joule effect [9].
Temperatures adjusting according to the wires speed
is made through the one-phased converter of high
frequencies 12.
The analysis of the processes which take place when
wiredrawing and the problems that occur, like wire tear,
has imposed the integration in a single control system
the 3 processes: regulating the wiredrawer, regulating
the annealing module and regulating the winding
mechanism (fig.3)

Bloc de
prescriere a
acceleratiei
CF1 M1
ML
RT
Blocul de
comanda
vectorial
CF2 M2
TC
TM2
TT fir

RP RF CFnalt S
TP
TV fir
Ts
rez
UTT
Vpr
Ppr.
BLF

Fig. 3. The structural scheme of the control system
3. VECTOR CONTROL SYSTEM OF THE
WINDING MECHANISM
In the following scheme (fig.4) is represented the
simplified structure of the winding mechanisms vector
drive, in which the pillar elements of this drive are
Fig.2 The functional scheme of the control system of the wiredrawer and of the annealing module
ului cu modul de recoacere
presented. The regulating of the wires tension force at
winding takes places in a direct way, using a transducer
for determining the tension force in the wire.
The scheme has 3 contours with subordinate regulating
of the internal of current, speed and the outer contour of
the wires tension force. Changing the regulating
modes is performed automatically after the influence of
the tension regulator over the limit block. In case the
wire is not a whole component of the regulator it drives
the regulator into saturation. The limit value is
prescribed by the signal Upv, prescribes the necessary
speed to an empty winding.
The force of stretching will start to rise and the tension
regulator will exit saturation and allow the contour of
stretch force regulator to work, considering that the
angular velocity of the drum is prescribed to be higher
that the linear speed of the drum.
At wire breakage a reverse process will start, the signal
from the tension force regulators exit will start to rise
until saturation. The windings speed will also start to
rise. To stop a full winding it is necessary to decrease
the limit value of the tension regulator until it reaches
nil. The multiplication and division device provides the
granting of the speed contour at function with
weakened magnetic flux or with changing the inertia
summary moment at the motor shaft. The law of
modification for the wires tension force is ensured by
the correcting block of tension forces prescription.
HRV(S) HRCA(S)
HRCM(S) HRF(S)
HRT(S)
KTF
KTCA
KTV
KTT
BL
KTCM
KCF
1+TCFS
1/RE
1+TSS
KrLr
1+TrS
KCE
1+TCFS
1
JS
1/RE
1+TSS
3
2
pkr
BCTP
J
Jo
KTF
Esy
Esx
rx
MS
HBob(S)
T
UPF
-
+
-
-
UPV
UTF
Isy
rx
Usy
Upc
URCA
Upv
UPT
BCRB
Calculul mome
ntului
de inertie
T
Fig. 4 Simplified structural scheme of vector regulation system for speed and tension force [2]
The correction block of the prescribed tension BCTP
represents a proportional controller with a factor:
1
TB
CPT R
B
R
k k
R
| |
=
|
\ .
( 1 )
Where
R
k - reserve coefficient, decreasing the influence
of the windings radius on the tension force, being
chosen
R
k =1,
TB
R - radius of the windings drum;
B
R - radius of the winding.
BCRB is calculus block of the windings radius.
3.1 Calculus of the magnetic fluxs canal
The structural scheme of the magnetic fluxs canal at a
vector control includes two loops of automatic
regulation: the internal loop of the magnetization
reactive current I
sx
=I
m
and the outer loop of the
magnetization flux (fig.5).

HRCM(S) HRF(S)
KTF
KTCM
KCF
1+TCFS
1/RE
1+TSS
KrLr
1+TrS
Esx
UPF
-
TF
TCM
CF RCM BLCM RF CS CR
Im
Usx
URC
URF
URCM
Fig.5 Structural scheme of the magnetic fluxs canal
The turning system of coordinates x-y is oriented after
the rotor flux ( )
, 0
r rx r ry
= = = , which ensures
the simplest structure of the SRA. This scheme does not
take into consideration the ABC /-, -/x-y and
reverse x-y/ - and -/ABC,
In the outer loop a magnetization currents limit block is
introduced (BLCM).
3.2 Calculus of the magnetization currents loop
Having determined the parameters of the motor,
belonging to the winging mechanism, we make the
calculus for the system regulation loops. The frequency
converter can be approximated with a first order
element

( )
( )
( ) 1
SX CF
CF
c CF
U S k
H S
U S T S
= =
+
(2)
Where:

.
2
3
sx N s
CF
CN CN
U U
k
U U
= = (3)
T
CF
=0,005s-inner constant of the CF without a
prescription integrator element. If a Hall type current
transducer is chosen, then it can be described through a
noninertial element

TCM.N
TCM
SX.N
U
k =
I
(4)

Tuning of RCM is made, relative simply, based on the
criteria of the module of the transfer function of the
closed loop of current

( )
( )
.
1
2 1
d
d c
c c
H S
T S T S

=
+
(5)
Where:
c
T

- the small constant (uncompensated by the

controller) of the currents loop
The RCMs regulation object

( ) ( ) ( ) ( )
( )( )
.
1/
1 ( ) 1 ( ) 1
1 1
ORC CF CS TCM
CF TCM E
CF S TCM
OR C
C S
H S H S H S H S
k k R
T S T S T S
k
T S T S

= =
=
+ + +
=
+ +
(6)
Where: 0.005
C CF
T T S

= = ;

.
CF TCM
OR C
E
k k
k
R

=

(7)
The current loops transfer function

( ) ( ) ( )
. . d C RCM OR C
H S H S H S = (8)
As a result, if the following equals
( ) ( )
. .
d
d C d c
H S H S =



d
dc
RCM
CRC
H ( ) (1 )
H (S)
2 H ( )
S
CRC
S T S
k T S S

+
= ~ (9)
The RCMs controller be a PI type. The time constant
of this controller compensates the big constant of the
loop the rotor constant T
IZ.C
= T
S
=0,248 S
The RCMs integration constant is:

. .
2 2
CF TCM
I C OR C c c
E
k k
T k T T
R

= = (10)
The coefficient of RCMs proportional piece:


.
.
IZ C
RCM
I C
T
k
T
= (11)
The transfer function of the closed current loop



.
.
2 2
( ) ( )
( )
( ) 1 ( )
1/
2 2 1
SX d c
BC
PC d c
TCM
c c
I S H S
H S
U S H S
k
T S T S

= = =
+
=
+ +
(12)
where: 1/
TCM
k - the inverse transfer function of the
TCM, introduced in the prescription currents circuit
( )
. OR C
H S .

3.3 Calculus of the exterior loop of flux
The transfer function for the flux transducer

| |
( )
/
RF
r x
U S
k V Wb
TF

=
(13)
Transfer function of this loop controller:
CRF SC CR 2 2
H (S) H (S) H (S)
(2 2 1)(1 )
CRF
r
k
T S T S T S

= ~
+ + +

where:
.
TF r r
OR F
TCM
k k L
k
k

= (14-15)
For tuning of the RF flux controller we use the same
criteria of the module with its desired function
( )
( )
.
2 2
1
2 2 2 1
d
d F
F c c
H S
T S T S T S

=
+ +
16)
The necessary transfer function for the RF is
analogically determined, gaining a PI controller

d
d.F
RF
. OR.F
H ( ) (1 )
H (S)
H ( )
S
OR F F
S T S
k T S S

+
= ~ (17)

where: 2 2 0.01
F c CF
T T T S

= = =
The isodrome constant of the flux regulator, in this case:
.
0.813
IZ F r
T T S = =
The RFs integration constant:

. I OR F F
T k T

=

(18)
The proportional amplification constant:

.
.
IZ F
RF
I F
T
k
T
= 19)

3.4 Calculus of the motors speed vector control
canal

The calculus of vector control canal of the, winding
drums drive, motors speed has, the inner loop of the
active stator current, connected in cascade, I
s y
=I
r
with
the RCA regulator and an outer speed loop (RV) and a
speed transducer (fig.6).
This canal includes three DMD multiplication-division
devices of the parameters at the RVs exit, and another
one at the current loops exit
HRV(S) HRCA(S)
KTCA
KTV
KCE
1+TCFS
1
JS
1/RE
1+TSS
3
2
pkr
J
Jo
KTF
Esy
MS
-
UTF
Isy
rx
Usy
Upc
URCA
Upv
Fig.6 The simplified structural scheme of the speeds
vector control channel
The division devise at the RVs device is determined by
the fact that this controller generates a prescription
signal for the motors electromagnetic couple, which is
proportional with the
r
flux and the active stator
current I
SA
I
r
.
As consequence, the prescription signal for the active
stator current:
RV
PCA
TF
U
U
U
= (20)
The division device at the RVs exit is meant for the
couples protection according to drums inertial variable
momentum.
3.5 Calculus of the active stator currents loop
The active stator current transducer must be chosen with
the same exit signal U
TCA.N
=3,5 V at a nominal current
of 3.5 A. The current, being twice as much, at the
RCAs entrance a voltage divider with a 0,5 coefficient
is introduced

.
.
TCA N
TCA
CA N
U
k
I
= 21)
The converters transfer function is the same as in the
reactive stator currents case
( )
1
CF
CF
CF
k
H S
T S
=
+
22)
Where:
.
; 0.005
sy N
CF CF
CN
U
k T S
U
= =
0.005 .
C CF
T T S

= = - the uncompensable constant of

the currents loop.
Thanks to the currents open loop, we get an current PI
controller with transfer function:

.
. .
1 1
( )
2
IZ C S
RCA
I C OR A C
T S T S
H S
T S k T S

+ +
= =

23)
Whre:
.
0.248 .
IZ C S
T T S = =

. .
2
I C OR A C
T k T

= (24)
The RCAs amplification coefficient

. IZ C
RCA
IC
T
k
T
= 25)
The transfer function of the currents closed loop:

2
2
1/
( )
2 2 1
2
2 2 1
TCA
BC
C C
C C
k
H S
T S T
T S T


= =
+ +
=
+ +
(26)
3.6 The calculus of the speeds loop
We pick a speed transducer with a transfer coefficient:

. TC V
TV
rN
U
k =
O
(27
)
The inertial summary momentum of the drum and
motor:
( )
2 2 2
/
M T M B T TO R
J J J J m R R i
E
= + = + 28)
Where:
B
m =10 kg ;
T
R =0,15m;
TO
R =0,05m
The transfer function of the speed regulation object:

( )
.
.
2 2
3
( ) ( ) /
2
2 1
OR V BC TV r r
OR V
C C
H S H S k p k J S
k
S T S T S

E
= + =
=
+ +

(29)
Where
.
1.346
ORV
k =
If we start from this transfer function, thanks to the
speeds closed loop:

. 2
1
( )
(2 2 1)
d
d v
V C C
H S
T S T S T S

=
+ +
30)
Then we get a pure proportional regulator for speed:

.
. . .
1 1
2
d
d v
RV
OR V OR V V OR V C
H
H
H k T k T

= = = (31)
The speeds loops transfer function closes with a
proportional regulator is:

( )
2 2
1/
( )
2 2 1 1
TV
BV
C C C
k
H S
T S T S T S

=
+ + +

32)
But a pure proportional speed regulator does not provide
a stationary error reporting to the motors load couple.
The cables winding mechanism does not require a null
stationary error, which is why we choose a PI speed
regulator.
For simplifying the grant of the system, the whole drive
of the wiredrawer and of the winding mechanism is
equated to a transfer function of second degree.
Following this equation we get the following structural
scheme (fig.7.):
HRT(S)
DLT
Upv
1
1+TEPVS
HBV(S)
RT-RTO
2
1
ired
ECUSk
Lk
FP
UTT
1
S
1
TT
FT
V
Fig.7. The simplified structural scheme of the drive
system
The transfer function of the speed loop:

2 2
0 0
( )
2 2 1
AE
BV
k
H S
T S T S
=
+ +
(33)
Where:
0
2 0.01
CF
T T s = =


.
0
1 1
2
Cu fir
T T
AE EPV
TV r k
E S
R R
k k
k i L

=

(34)



1
2
RT
AE T
k
k T

= (35)




4. THE MODEL OF THE WIREDRAWING
MACHINES CONTROL SYSTEM

The Simulink model of the wiredrawing machines
integrated control system (fig.8) contains drives of : the
module of wiredrawing, the mechanical parts
movement equations, and wire annealing and winding.
The mathematical models of the wiredrawers drive
contain transfer functions of the drive motor and of the
frequency converter. The scalar drive of this motor is
made of the following reason: the wiredrawer does not
require a drive with high dynamical parameters, the
motor having functioned on its natural characteristic,
without feedback loops.
The cascade vector control system if the winding
drums motor speed is made of an outer loop of the
active stator current I
s y
=I
r
with the RCA regulator, the
outer speed loop (RV) and the correction loop of the TT
transducers tension force.
The mathematic model of the wiredrawing and winding
machines parts contains the following relations [10]

.
2 1
2 2
.
2
( ) ( ( ) ( ))
( )
( )
( )
1
( ) ( )
( )
Cu cond
T LM LM
k
T
LM M
red
M din
E S
F S V S V S
L S
R S
V S
i
S M S
J S
e
e
E

=

=
`

)
(36)
where:

F
T
tension force;
V
LM1
-wires linear speed;
V
LM2
-winding mechanisms drums linear speed;
S
cond.
-conductors section;
L
k
-lathes work length;
R
T
-drums radius;
E
Cu
-elasticity coefficient of the metals wire.

When modeling of the annealing module, because of the
loads active character, the frequency correction of the
phase shift was excluded, and the loads impedance has
a constant value. The converter is esteemed with a first
degree element, and the force section has the following
relation as basis:

2
ind S S
P I R = (37)


Drive module of
wiredrawing machine
Module drive winding mechanism
Annealing module
Work Machine
Prescribing element
of acceleration
prescribing
tension force
Ms1
Ms2
W 1 2
tension force
power the induction
element's
W, M1
W, M2
V liniar 2
Uc1
Uc
magnetic fluxi
Ms
prescribed tension
force
Tension correction
Engine speed M2
Ms
Uc
W, M1
W, M1
W, M2

Fig.8 The Simulink model of the control system

5. SIMULATION RESULTS

Based on the developed model the transitional processes
at start, acceleration and deceleration of the vector
control winding machines drive, the study of the wires
tension force in dynamical modes, the dependence of
the transmitted power to the inductor of the annealing
module compared to the wires linear speed, adjusting
the regulators processes etc.
From fig.9 and fig.10 a following fact is observed: the
control system of the annealing module ensures the
proportional regulation of the elements energy
depending on the wires linear speed, after it has been
wiredrawn.
An overregulation of the tension force can be observed
when simulating the winding systems, without
considering the reaction of the tension force, (fig.11)
which may lead to tearing of the wire. As a result, in the
control system, a tension s force transducer was
introduced for eliminating of this overvoltage and for
ensuring the prescribed value (fig.10.).
6. CONCLUSIONS
In order to improve the regulation indices and to gain in
productivity of the wiredrawing machine a single
control system was developed through integration of the


4
6
8
10
2
V, m/s
5 10 15 20 25 30



winding and wiredrawing machines drive control, as
well as of the annealing module, subsystems. Based on
the transfer functions the mathematical model for the
system: of automatic regulation for the wires tension
force and of regulation of energy flux for the annealing
module depending on the wires linear speed has been
eveloped.
Fig. 9. The variation of the wires linear speed

The computer simulation of the developed control
system proves: the adequate behaving of the
wiredrawing machine for different variations of the
prescription signals and for different perturbations; the
optimization of the dynamic and static processes vs. the
quickness and exclusion of oscillations and
overregulation of the controlled dimensions.
5 10 15 20 25 30
2000
4000
6000
8000
10000
12000
14000
P, W
T, s




-5
0
5
10
15
20
2 4 6 8 10 12 14 16 18 20
T,s
F, N








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3. .. .
. M.: . 2001.
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machines.aspx
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http://morgan-koch.com/
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http://factory.dhgate.com/cable-manufacturing-
equipment/b24-stainless-steel-wire-drawing-
machine-p44716833.html
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sv.com/index.php
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motoare asincrone. Tez de licen, Chiinu, 2010.
Fig. 10 The variation of the induction elements
emited energy
Fig. 11 The tension froce when regulating
without a reaction loop

0 5 10 15 20 25 30
0
1
2
3
4
5
6
Time (Seconds)
F,[N]
Fig. 12 The tension froce when regulating with a
reaction loop