(a) Distance control for a given destination floor (b) Distance control for a given parking request

Figure 1 TD3100 Frequency Converter Distance Control Timing

III. Two-point Fixed Distance Positioning Using TD3100

For two-point fixed positioning, the system functions similarly to an elevator with only two floors. Limit switches must be installed at both ends, and self-learning between the two points is performed to enable direct distance control based on the parking request.

1. Self-learning

The self-learning connection is shown in Figure 2(a). Short-circuit UPL and DWL, and connect the left and right limit switches in parallel. Input the flat layer signal to UPL and DWL. The self-learning process should start from a position beyond the left or right limit. If it cannot leave the limit, the position can still be learned, and accuracy can be adjusted by modifying F4.07 or F4.09 during normal operation. Set F4.00 to 2 and F4.01 according to the position width for automatic calculation of the frequency division factor. During self-learning, close FWD and SL to start the process. After the limit switch is triggered, remove the FWD command and complete the learning. Check the values of F4.08 and F4.09 to ensure they are recorded correctly. Adjust F3.11-F3.16 if acceleration/deceleration time is too long or short.

(a) Self-learning wiring (b) Normal operation wiring

Fig. 2 Using TD3100 for two-point fixed positioning

2. Normal Operation

Calculate and set F1.07 according to Formula 1, where D is the diameter of the roller at the control line speed, and R is the mechanical reduction ratio. Set F5.00=15, select the X1 terminal as the distance control enable function, and adjust the S-curve according to the required process efficiency. Finally, adjust F3.02 and F3.21 to fine-tune the parking accuracy.

According to Figure 2(b), wire FWD, REV, and INS commands. During normal operation, only the FWD/REV signal is needed. The INS terminal is used for jogging. When jogging, the INS signal is valid first, followed by the FWD/REV signal to control movement left or right.

3. Application in Glass Screen Transfer Machine

The structure of the glass transfer machine is shown in Figure 3. It is driven by a 2.2kW motor with a rated voltage of 380V, operating frequency of 50Hz, current of 5.0A, and speed of 1420r/m. The gear ratio is 1:17, and two proximity switches are installed. The distance between the first and second switches is approximately 1400–1800mm, and the load of the transfer platform is about 150–170kg. The system requires movement and positioning between the two limit switches with an accuracy of ±3mm and a single-stroke completion time of 2–3 seconds.

According to Figure 2(a), set F4.00 = 2, use the INS and REV signals to open the car to one side, then close FWD and SL to complete self-learning. To improve efficiency, set the S-curve parameters to maximum, set F7.00 and F7.01 to zero, and set F3.00 and F3.01 to zero. Set F3.02, F3.11, F3.12, F3.14, F3.15 to 2.400m/s², and F3.10, F3.13, F3.21 to 2.00m/s². Set F3.02 to 0.3m/s². The result is smooth operation that meets the process requirements and achieves a servo-like positioning effect.

IV. Multi-point Fixed Distance Positioning Using TD3100

For applications like three-dimensional warehouses and garages requiring multi-position control in X, Y, and Z axes, the TD3100 can greatly simplify the circuit, reduce costs, and enhance reliability. With up to 128 floors, controlling the destination floor is straightforward. The system using TD3100 in a stereoscopic warehouse is shown in Figure 4. In this setup, UPL and DWL signals can be connected to leveling switches or directly to COM. FLE is the target floor enable terminal, and INI is the current floor initialization terminal. From the comparison in the figure, we see that communication control simplifies the circuit, saves resources, and reduces costs. Note that this feature may require customization. Before application, floor height self-learning is necessary, following the method described earlier and setting F7.00 according to actual conditions.

(a) Binary floor control (b) Communication control

Figure 4 Stereoscopic warehouse system with TD3100 converter

V. Two-point Distance Control Method Using TD3100

When implementing two-point distance control with the TD3100, the method is similar to two-point fixed positioning. The main difference is that the floor height value (F4.09) must be manually or automatically adjusted in parking mode before running. Since manual adjustment is inconvenient, it is usually controlled by a higher-level computer. Additionally, for distance-based control, two limit switches are required for positional discrimination to prevent mechanical shocks during movement.

A typical application is in multi-motor, multi-axis high-precision distance control systems such as smart digital stage control. The modern stage drive system using PROFIBUS-DP fieldbus control is shown in Figure 5. The system is controlled by a PC, with a built-in Siemens PROFIBUS master board (CP5611 or CP5412) for manual and automatic control. The adapter uses the TDS-PA01 produced by Emerson, interfacing directly with the TD3100. The purpose of using PROFIBUS is to achieve high real-time control accuracy and faster response times, ensuring both speed and precision.

Figure 5 Modern stage drive system with PROFIBUS-DP fieldbus control

VI. Conclusion

Beyond elevator applications, the TD3100 can be applied in various systems requiring positioning and distance control. It effectively reduces hardware design costs and software development workload while improving system reliability.

References:

1. TD3100 Inverter Product Specification

PVC Shrink Film

Good transparency,High strength

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