VFD Application Case Study: Box-Drawing Facial Tissue Machine
The box-drawing and folding machine, also known as a folding machine, is a specialized device that processes rolled base paper through rewinding, embossing, cutting, folding, and perfume spraying operations. It then completes automatic packaging for subsequent manufacturing steps to produce daily-use box-drawing facial tissue paper. A critical requirement is maintaining fixed proportional linear speeds across unwinding, embossing, and cutting processes to ensure product quality and operational efficiency.
- Difficult debugging and complex mechanical adjustments
- High raw material loss due to paper tearing or compression
- Low production efficiency with frequent downtime
- High maintenance costs from wear-prone mechanical components
- VFD and motor connect to main machine and paper rack via synchronous belts or chains
- Speed ratio adjusted through pulley ratios
- Advantages: Simple control logic
- Disadvantages: Complex mechanical structure, high mechanical costs, troublesome maintenance
A leading paper machinery manufacturer adopted AnyHz's advanced VFD solution, transitioning from mechanical synchronization to independent host and paper rack control with PLC-based whole-machine logic.
| Component | Model | Motor | Function |
|---|---|---|---|
| Main Drive | FST-650L-7R5G/011PT4 | 7.5kW asynchronous motor | Host speed control |
| Paper Rack 1 | FST-650L-2R2G/4R0PT4 | 2.2kW asynchronous motor | Unwinding tension |
| Paper Rack 2 | FST-650L-2R2G/4R0PT4 | 2.2kW asynchronous motor | Unwinding tension |
| Controller | PLC with RS485 communication | — | System logic & HMI |
- Master Frequency: PLC sends RS485 signal to set host VFD operating frequency via HMI touchscreen
- Slave Synchronization: Host VFD's high-speed pulse DO output feeds to slave VFD's X5 terminal as frequency reference
- Tension Control: Achieves constant paper tension through linear speed synchronization between master and slave drives
- Operation: Start/stop commands and frequency settings managed through display interface
- Cost Reduction
- Eliminates paper squeezing and tearing incidents
- Significantly reduces raw material waste and scrap rates
- Quality Improvement
- Clean, flat tissue cutting without compression damage
- Consistent product appearance and texture
- Production Efficiency Gains
- Stable operating speed: 100 meters/minute
- 20%+ efficiency improvement compared to traditional solutions
- Significant enhancement in both speed and operational stability
- Extended Equipment Lifespan
- Improved automation reduces manual intervention
- Lower maintenance requirements and downtime
- Precision Control: Integrates position, speed, and torque control with high accuracy
- Human-Machine Interaction: Intuitive touchscreen interface for parameter setting and monitoring
- Synchronization Method: High-speed pulse output ensures real-time speed matching between master and slave drives
- Scalability: Modular design allows easy expansion for additional paper racks or process stages
The AnyHz FST-650L series VFD solution successfully transforms box-drawing tissue machine operations by replacing complex mechanical synchronization with intelligent electronic control. This implementation delivers:
- Economic Benefits: Reduced material waste and maintenance costs
- Quality Assurance: Consistent, damage-free tissue processing
- Operational Excellence: 20% efficiency gain with stable high-speed production
- Future-Ready Design: PLC-based architecture enables easy upgrades and IoT integration
By combining precise tension control with user-friendly HMI operation, AnyHz provides a cost-effective, high-performance automation solution for the paper manufacturing industry.
