Winding device JUMBO

The winding device is designed for the efficient winding of rubber roofing material used to cover building roofs. It consists of two separate winding units, with only one of them operating at any given time. The second unit is ready for immediate use during the roll change, eliminating downtime and allowing production to continue uninterrupted. This solution ensures that the machine before the winder does not need to be stopped, thus optimizing production continuity.


A material accumulator is installed between the winder and the machine, which stores the necessary volume of material during roll changes. This accumulator prevents any downtime and enables a smooth transition between winding units.


Material pulling is carried out using a pull roller located above the winders. The pulling speed must be synchronized with both the production line speed and the winding units' speed to ensure optimal material tension. This tension is crucial for the material to be properly and evenly wound onto the roll, ensuring a high-quality wound product.

CUSTOMER REQUIREMENTS

  • Complete overhaul of the distribution cabinet (wiring, inverters, safety elements, power supplies, safety, the cabinet itself, PLC, inputs/outputs)
  • Redesign of the control panel (HMI display, control buttons, new enclosure)
  • Motor replacement
  • Replacement of the safety unit (PILZ)
  • Complete reprogramming of the winding device
  • Optimization of the winding process, improvement of roll change efficiency, and elimination of material wrinkling

Preparation

Identification and procurement of all necessary components 

Production

Manufacturing of the distribution cabinet, cabling...

Testing

Testing sensors, commissioning motors, PLC, invertors 

Programming

Final programming, machine startup

BLOK DIAGRAM



CONTROL CABINET 

During the retrofit of the distribution cabinet, a complete modernization of the electrical installation was carried out. All the wiring in the distribution cabinet was replaced, including all the safety and switching devices. The original control system was replaced with a new Lenze c520 PLC, which provides modern and efficient system control through new input-output modules.


Four new Lenze i950 frequency inverters were also installed in the distribution cabinet to ensure precise motor control. Due to the nature of movements with high inertia, braking resistors were added to each motor to efficiently absorb the energy generated during braking. This braking resistor system helps to safely and controllably stop the device without damaging the motors or other components.


The communication between the individual system components is carried out via the EtherCAT protocol, which ensures high-speed and deterministic data transfer with minimal latency. This protocol is optimized for industrial applications where precise and reliable real-time information exchange between control units and drives is critical.


All key control elements, including the PLC and frequency inverters, are from the same manufacturer, ensuring maximum compatibility between devices. This minimizes the need for complex integration of different protocols or interfaces, simplifying system configuration and subsequent maintenance. Diagnostics and troubleshooting are thus more efficient, as the system provides a unified interface for monitoring and controlling all elements, leading to greater reliability and easier management of operations.

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                  Picture 1. Control cabinet before reconfiguration  ​ ​ ​ ​        ​Picture 2. Control cabinet after reconfiguration 

CONTROL PANEL

Similarly to the distribution cabinet, the old control enclosure was replaced with a new one. The original control via physical buttons was upgraded to control via a Lenze v450 HMI display, which significantly simplified not only the operation but also the wiring of the control panel. This type of display allows users to visually monitor and interact with various machine functions through a touch interface, eliminating the need for many physical buttons. Communication between the display and the PLC is carried out via LAN wiring, with the display also powered through a PoE injector.


With the new HMI panel, a new visualization was created, which is simple, clear, and provides seamless control and monitoring of the machine. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​


​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​         ​Picture 3. Old Control panel             ​Picture 4. New Control panel 

REPLACEMENT OF MOTORS AND THE SAFETY UNIT 

As part of the machine modernization, the main winding motors and the pull roller motor were replaced. This replacement involved the complete removal of the old motors, installation of the new ones, and their integration into the system. The motor replacement process required precise coordination, not only due to the physical placement of the motors but also for their electrical connection and integration into the control system. The new motors offer higher efficiency, better performance regulation, and reduced energy consumption, contributing to the overall modernization and optimization of the machine's operation.


The old Pilz safety unit was replaced with a new, more compact unit that allows communication with the control system.


PROGRAMING

The goal of the programming was to optimize the entire winding process. Care had to be taken to ensure that the synchronization of pulling forces between the pull roller and the winding units was consistent to prevent excessive tension or slack in the material. The pull of the roller was controlled by a load cell placed at the winder's input, which provided feedback for force regulation.


The tension and speed of the winders were dynamically managed using specialized FAST modules from Lenze.Learn moreThese modules enabled automatic reduction of tension as the diameter of the wound material increased, ensuring optimal machine operation. The calculation of the current winding diameter was also managed by these FAST modules, which are designed for precise control of winding processes. These modules represent an advanced solution for complex real-time control tasks, ensuring high efficiency and reliability throughout the system.


After reprogramming the machine and fine-tuning the mechanical irregularities discovered during the overhaul and testing, the entire winding process and roll changes were made more efficient. Additionally, the wrinkling of the material, which was the customer's primary concern, was eliminated.


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