Drive System Modernization for ZFWZ 630 Gear Hobbing Machine

The control system repair of the ZFWZ 630 gear hobber involved implementing a modern thyristor converter for precise control of the existing VEM MBC 180M2-902 compound-wound DC motor (Pn=10kW, In=53A, Un=220VDC).

The integrated Mentor MP digital drive ensures stable speed regulation by adjusting the armature voltage using feedback systems (tachogenerator/encoder). This represents a major technological advancement over the original GDR-manufactured system, which relied on less precise field current regulation. The system is powered by a dedicated 3x400V / 3x160V matching transformer.

Hardware Deployment Specifications:

• ✓ Main converter: Mentor MP 75A4 (Control Techniques Nidec), Un=3x400V, In=75A, non-regenerative DC industrial drive.
• ✓ Protective devices: High-speed semiconductor fuse kit (100A) protecting the converter's thyristor modules.
• ✓ Auxiliary systems: Control electronics power supply transformer and a dedicated motor field excitation circuit.
• ✓ Enclosure system: Ventilated wall-mount enclosure (800x600x300) with an active cooling system, integrated onto the side panel of the existing control cabinet.

Scope of Project Execution:

• ✓ Development of electrical schematics and documentation within the EPLAN Electric platform.
• ✓ On-site hardware assembly, wiring, and electrical integration.
• ✓ Drive parameter configuration, system commissioning, and full-load operational testing.