EuroWire July 2019

Technology News

Reelex offers control system retrofits

Debuting on the single-spindle D-750 in 2018, the company now offers the latest G3 control system on new D-750s and dual-spindle D-1500s. Importantly, G3 is also available as a field retro-fittable upgrade to G1 machines – replacing the entire control system on these older machines via a two-day on-site install. Interfacing with the winding module is a high-definition Red Lion Graphite 12" HMI running proprietary Reelex software. This software brings the equipment into the 21 st century, with real-time troubleshooting, multi-language support, recipe functions, networking functionality andmore. The advantages of G3 are significant, as it simplifies, improves reliability, adds features and builds upon the success of the G1 and G2 systems. By reducing all control functions in size and placing them on a single PCB, users can expect the following benefits: • Reliable design: Printed and assembled by a PCB manufacturer, the winding module circuit board reduces human error in the manufacturing process and undergoes rigorous quality control inspection prior to use • Simplified maintenance and minimal downtime: The G3 winding module replaces up to six individual circuit boards with a single Reelex winding module. If the board has an issue, users can be back up and running in a matter of minutes by simply swapping the board with a new one. Troubleshooting or checking to determine which board has the error is eliminated

• ‘Bulletproof’ setup: No tuning or setup is required. The winding module is programmed and ready to start out of the box • Digital inputs: Digital feedback improves reliability, eases troubleshooting and improves accuracy and ease of drive tuning • No thumbwheels or keypads: G1 D-750 and D-1500 users will be pleased to know there are no thumbwheels or keypads – all inputs are now handled by the touchscreen HMI • Proprietary HMI software: The custom HMI software provides intuitive setup and control, and features product recipe, integrated help screens, multi-language support, coil calculator andmore • 24 volt operation: Low-voltage power increases safety and serviceability • Cleaner, consolidated components: Opto racks are consolidated, power supplies are simpler and easier to service, and wiring is clear and easy to troubleshoot • On-screen troubleshooting: Many issues can be diagnosed without having to open the cabinet, as motor performance, valve and switch positions and equipment setup are all visualised on the HMI. Remote access is also available for real-time diagnostics by technicians • Machine status feedback: The status of the payoff, machine stop circuit, spark or lump fault and other information is readily available on screen Reelex Packaging Solutions Inc – USA Website : www.reelex.com

REPLACING nearly all of the circuitry in legacy “G1” Reelex machines, Reelex has developed its own G3 “winding module” printed circuit board (PCB). This control board combines encoder monitoring, processing, calculations, I/O and interfacing onto a single integrated unit. These components on the board interact with existing I/O to control machine functions. Custom controls are not new for the company. Unlike many equipment manufacturers who use PLCs for machine controls, the high-speed, high-precision nature of the Reelex coil requires proprietary, custom-made controls. From the 1970s through to the early 2000s, the company’s synchronisation of the coiling head (mandrel) and traverse motors on its machines had been handled by a variety of circuit boards working together. These “G1” control systems used thumbwheels and LED readouts to give the operator control over coil density, payout hole size and other machine functions. Today, these legacy controls are still in use on a variety of older equipment, even as parts are becoming obsolete or hard to find. As a result, these older machines are overdue for upgrades. Starting in the early 2000s, Reelex controls became industrial PC-based, with its programmers customising the PC at the processor level and building its controls into the off-the-shelf motherboard. These “G2” controls were paired with a Red Lion touchscreen HMI running the company’s software, opening the door for the latest G3 platform. and wire drawing machines in a totally green application. Exceptional cleanliness obtained in a glossy finish and plating quality permits wire direct brass coating, copper coating, galvanising, plating, Al and Cu cladding and wire cleaning prior to patenting, annealing, plastic coating, etc. The PWC incorporates new technology that enables normal plant cold water to be converted into a unique cleaning medium generating pressure wetting/ contaminants extreme pressure extrusion/hydrodynamic cavitations displacement and contaminants flush out. polishing, in-line with The PWC system simultaneously performs drawn wire cleaning

Advertorial on behalf of Decalub Wire green cleaning for plating and glossy finish

further smoothly polished under high pressure generated by the unit, enabling the wire to leave the unit very clean with white-metal appearance with reflective finish and totally dry.

The

PWC

system

provides

the

ultimate

combination effectiveness:

of

simplicity

and acid-free, caustic-free, without ultrasonic, without chemicals, hermetically sealed zero-emission system, no fumes and no foam. Economical and environmentally friendly, the system provides significant process savings in the production of clean wire. The PWC unit is compact and can be easily installed on the finishing block (last block) of a wire dry drawing machine.

▲ ▲ Wire cleaned for plating finish by PWC system

system can be used with a conventional emulsion diluted with water at three to five per cent concentration. The PWC system effectively loosens and removes lubricant residue from base material and is particularly recommended for cleaning applications with wires drawn upon severe conditions resulting in increased heat and burnt lubricant tightly bound to the wire surface and embedded in micro-cavities, which are

Decalub – France Email : info@decalub.com Website : www.decalub.com

For a clean mirror reflective wire finish, for decorative applications, the

31

www.read-eurowire.com

July 2019