Web Transport and Tension Control

Web tension controlWeb tension is a critical element of numerous manufacturing processes. No matter how demanding a production process is, either the material or the running parameters, our control systems ensure that the correct web tension is reliably maintained. At Optima, we have designed, built and applied high quality variable speed drive control systems to an impressive range of web tension applications.

Our clients enjoy better control, increased reliability, improved performance and uplifted productivity; because not only are we expert electrical engineers, at Optima we have a comprehensive understanding of the control system as a whole. We appreciate that every closed loop system includes mechanical components, transducers, the materials being processed and many product-conditioning elements. Our vast experience designing systems that accommodate and control all these variables ensures the systems we produce perform well in every application.

Scope of Supply:

  • A comprehensive survey of the existing machine control strategy using our in-depth knowledge of web applications to identify areas requiring improvement or factors that are limiting machine performance
  • We develop a full machine specification: Here we define how the new control system is to operate and how any existing limitations will be overcome. We believe that involvement at all levels from management to operators is paramount to the success of the upgrade.
  • We design a fully integrated drive control system Our system will fully satisfy all of agreed specification criteria and, more importantly, your operational requirements.
  • We design and schedule the upgrade to fit with your machine availability. Prime project management of this can be provided on request.
  • We install all of the control elements using our personnel and selected, approved subcontractors. Machine downtime is a significant factor in any project. The skill of the installation team and quality of their work is critical.
  • We fully commission the new automation equipment and provide baseline post-commissioning performance data for the machine. The best machine ownership experience follows best design practise and high-quality commissioning. These are core deliverables with every Optima system.

Partners:

Siemens

Rockwell

Parker SSD

Pilz

TTS

ABB

Previous Projects:

Coating line control system replacement

Upgrade of obsolete control system with over 100 integrated drives. Additionally, MPS compliant safety system was installed.

Slitting machine control system upgrade

Replacement of existing control system using Parker SSD DC drive controllers, Siemens S7-300 PLC, ultrasonic sensors, E-P converters.

Paper machine drives upgrade

New control system design and installed in a staged manner to minimise downtime. Conversion of original drives (multi-panel) to standard form units. Installation and commissioning.

Coating line control system replacement

Design and supply of variable speed drive control system for web transport and in-line coating processes.

Rewinder control system upgrade

Replacement of existing torque controlled DC drives and P.M. motors with equivalent AC vector drives and motors including load cell tension control in closed-loop format.

Learn how better tension control will improve your production processes in our free whitepaper here.

 

 

 

Recent Posts

Scalable motion control systems from Siemens and Optima

Optima are pleased to be able ot offer our holistic system approach for motion control applications in the field of basic automation

Using the single-axis servo drive systems, SINAMICS S200, S210, and the new controller SIMATIC S7-1200 G2 we are able to offer a competitive solution for Kinematics, Positioning Cams, Speed axis and a host of other functions.

SINAMICS S200, S210, and the new controller SIMATIC S7-1200 G2.

Performance and Scalability

• Enhanced processing power with dedicated communication performance and extended memory
• Supports up to 31 PROFINET devices and synchronized
program execution with PROFINET IRT
• High drive performance due to a fast current controller

Flexible machine safety

• A cost-optimized fail-safe safety hardware portfolio
• PROFIsafe communication for safe data exchange
between the controller and the drive system for safety
applications
• Drive-integrated basic and extended safety
functionality up to SIL3, PLe and Category 4

Efficient motion control

• Control of single axes, coordinated axes, and simple kinematics
• Integrated motion control technology objects simplifying
configuration
• Drive-integrated basic positioner function, SINAMICS EPOS

Increased data transparency

• Near Field Communication (NFC) for wireless access
to diagnostic and device data of the PLC
• SINAMICS Smart Adapter for wireless access between
the drive-integrated webserver and mobile devices or
to the SINAMICS Startdrive engineering software
• Drive-integrated webserver for easy commissioning

PLC and drive overview

All images (c) Siemens Automation

Optima are an approved Siemens Drive Systems Integrator with a 30 year track record of delivering results on complex automation applications

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