SHENZHEN, China – Shenzhen KEVAN Drive Technology Co., Ltd., a professional VFD manufacturer and industrial inverter supplier, today published a technical case study on the application of its KV600 series inverter in power pay-off racks for the wire and cable industry.
The wire and cable industry is rapidly advancing toward higher levels of automation. The growing demand for high precision and high reliability is driving continuous improvements in power pay-off systems. As a critical component in this process, the variable frequency drive (VFD) plays an essential role in controlling motor speed, improving process efficiency, ensuring product quality, and maximizing returns.
Overview: The Role of VFDs in Power Pay-Off Racks
Power pay-off racks in the wire and cable industry are typically classified as vertical or horizontal types. While their structures differ, both serve the same purpose: paying out wires under controlled tension. The VFD controls the motor’s pay-off speed, directly impacting production efficiency and finished product quality.
In the early stages of the industry, power pay-off systems primarily relied on imported VFD brands such as ABB and Siemens. However, with the continuous advancement of domestic manufacturing, locally produced inverters — such as KEVAN’s KV600 series — now offer higher cost-performance, lower maintenance costs, and faster, more responsive service. As a result, the industry is increasingly adopting domestic VFD solutions.
Composition and Working Principle of Power Pay-Off Equipment
A typical power pay-off machine pays out two or more wires. The wires pass through a balance bar mechanism. By monitoring the position of the balance bar, the pay-off machine can rotate forward, reverse, or stop at the zero point. After passing the balance bar, the wires enter a stranding machine, where two or more wires are twisted together to form the final product — for example, Ethernet cables are produced using this process.
Key Functional Requirements of Power Pay-Off Racks
A complete power pay-off system must meet the following functional requirements:
- The feedback rod must quickly and accurately find the zero point during startup
- The power pay-off rack must pay out wire stably during continuous operation
- Wire tension must be accurately maintained when the machine stops
Based on customer specifications for a power pay-off rack in a machinery factory, the VFD must achieve:
- When the pendulum is in the middle, the motor stops (zero point position)
- When the pendulum is at the bottom, the motor rotates in reverse with maximum frequency not exceeding 5 Hz
- When the pendulum is at the top, the motor rotates forward with maximum frequency of 30 Hz and fast response time
- The swing arm must not touch the limit point during upward or downward movement
- Swing amplitude must not be excessive when automatically finding zero point; the system must find zero quickly and accurately
- When the machine stops, the line must remain taut, not loose
KV600 VFD Application on Power Pay-Off Racks
To achieve the above functions, the KV600 inverter from KEVAN utilizes its built-in PID control functionality. The zero point of the feedback rod is first calibrated (the middle of the physical position, with PID input set to 50%). The feedback rod is connected to the PID feedback loop, and forward/reverse rotation is achieved by offsetting the feedback rod from the zero point. Additional functions can be tuned by adjusting PID-related parameters such as PID gain and PID feedback.
KV600 inverter wiring diagram
KV600 setting parameters need to be adjusted appropriately
Compared to the previous KV300 series inverter, which already met basic power pay-off requirements, the KV600 general-purpose inverter delivers significantly better control performance. Our company has optimized the PID control algorithm on the KV600, resulting in:
- Superior PID control performance
- High accuracy
- Fast dynamic response
- Reliable process control
These improvements ensure the reliability of process control in power pay-off applications, making the KV600 VFD an ideal choice for wire and cable manufacturers seeking to upgrade their production lines.
About Shenzhen KEVAN Drive Technology Co., Ltd.
KEVAN Drive Technology is a technology-driven enterprise integrating R&D, production, sales, and service of inverters, VFDs, industrial drives, and control systems. The company is committed to providing reliable, standardized products and customized solutions for customers worldwide.
With the launch of its new international website, KEVAN aims to better serve global customers in the wire and cable industry, as well as other industrial automation sectors.
Contact KEVAN Overseas Sales
Overseas Sales Contact: Mr. Li
Phone: +86-13725501611
Email: Service@kevaninverter.com
Company Address:
Room 501, Building 11, Nangang Second Industrial Park
No. 1026, Songbai Road, Sunshine Community, Xili Street
Nanshan District, Shenzhen, China
Welcome to visit the new international website of Shenzhen KEVAN Drive Technology Co., Ltd., your reliable partner for VFDs, inverters, and industrial automation solutions.