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Challenge:
A cable manufacturer wanted to build a wire winding machine for less than the cost of off-the-shelf general purpose winders.
Solution:
Most general-purpose machines use complex and expensive master-slave position following controls. Since this customer’s products were established and their winding requirements were predictable and consistent, a less sophisticated control solution would be sufficient.
The wire would be fed at a constant speed from an extruder, and the wire would be guided onto the spool by a linear positioning device. To get a uniform wind, the traverse speed of the guide needs to decrease as the circumference of the wire wrapped on the spool increases, and as the rotational speed of the spool slows down.
The solution used a rodless actuator (R3) for the traverse. A DC motor drives the actuator. Limit switches and a small PLC with analog input/output capability . The PLC uses discrete I/O to activate the DC drive to move the traverse between the limit switch positions. The PLC calculates the diameter of the roll based on a speed signal from a tachometer attached to the spool, and adjusts the traverse velocity as the spool speed changes.
Application Solutions
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