Software Key to New Web Converting Machine

A Recipe for Conversion: Drive and Control System, Easy-to-Program Software Help Summit Machine Provide a Precise Machine

By Todd Bauernfeind, Summit Machine

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For Summit Machine in Shoreview, Minn., precision is absolutely essential as it engineers, designs and builds custom web converting equipment for a variety of industries and applications.

Summit recently built a high-precision servo-driven web converting machine for a developer, manufacturer and supplier to the electronics industry that was launching a new product but had antiquated machinery incapable of production of the new line. Summit's challenge was to design a machine having a robust, yet flexible control system without the need to program all the advanced functionality from the ground up — a process that could make the machine cost-prohibitive.

"The customer really didn't have sophisticated web-converting equipment," says Russ Hubrich, engineering manager at Summit Machine. "They were built around brakes and very basic technology. This new machine was a step above. They had an old rubber-mixing machine with big gear boxes that they'd bought used, and it was worn out and oversized for what they were doing. The adjustment for the gas was manual. It was very crude. They were running material through it and moving it off-line and cutting it, and they wanted it all in one machine. Our new machine uses two web-converting rolls as the heart of the machine."

Built-in Functionality From the Ground Up
The web converter Summit designed and built for this application is a 20-axis converting machine that takes material compounds and precisely forms them against a substrate to create the final product, which usually resembles a soft pad and comes out of the machine as a sheet or on a roll (Figure 1).

The machine is composed of two sections with a curing oven in between. The front section has three unwinding spindles and a coating section with one fixed cylinder on the leading edge side and one movable cylinder on the finishing side that allows the operator to control the gap distance precisely. The backing material unwinds from the spindles and passes through the coating section as product is pumped in between to a given thickness.

The converted web material then passes through the curing oven to the back half of the machine where chill rollers, a main product rewind, and a slitter-sheeter are in place.

As the converted web material is cooled to room temperature using the chill rollers, it can be either rewound in a roll-to-roll process or cut into sheets. For the roll-to-roll process the materials go onto a rewind, which can also involve two other rewinds for liner removal if desired.

If the final product is requested in sheet-form, the material passes over the rewind and enters a nip conveyor. The nip conveyor uses two conveyors that are pneumatically loaded together to create a nipping action without crushing or deforming the final product. Afterward, the material goes through a standard shear-cut slitting head and die station. The liner is peeled back and replaced with a new one to eliminate wrinkles and then run through a precision die cutter so it can be cut into different sizes before moving to an output conveyor.

For flexibility, the machine can be split electronically into two machines allowing the web-converting section to run a roll-to-roll process while the slitting-sheeting section can run roll-to-sheet. Summit's customer was bringing a new product into production, so the new machine was critical. "We built two machines," explains Hubrich. "The first machine increased capacity; they could cure it in-line. The second machine went to another plant so they had redundancy."

More Flexibility, Less Programming
"Developing tension-control algorithms takes a bit of time and energy," explains Hubrich. "We buy discrete components and configure them and then figure out a way for them to communicate." To help develop the control system, Summit worked with local automation distributor Motion Tech Automation, which specified the Synax 200 control platform, a PLC and motion control solution from Bosch Rexroth.

"We found this Bosch Rexroth platform with a motion package," says Hubrich. "To get a machine like this up and running, you do some configuration in the motion end of the software and some tuning and you're done. You don't have to create it from scratch." Intelligent servo drives using SERCOS communication, servo motors and two operator interfaces rounded out the proposed machine specifications. "To start this from scratch would have made this project cost-prohibitive," explains Hubrich. "We had to get our customer's buy-in, so we proposed this as a solution. We talked about a few alternatives with discrete components, but that wasn't a good idea for them. They were very open to the platform we suggested."

Specifically designed for the converting industry, the Synax 200 is a freely scalable control and drive solution that helped Summit build in flexibility without a lot of time-intensive programming. "You can add as many drives as you want and change around your servos as you see fit," says Hubrich. The Synax 200 replaces wear-prone mechanical drive elements with electronic line shafting (ELS) and uses tightly synchronized digital servo drives and dynamic servo motors running off a standardized control platform. "The original machine had only two motors, so there was no line shaft," explains Hubrich. "The old rubber-mixing machine had three rolls. The only other option was line shaft, and that was never a consideration for us. There's no flexibility with line shaft."

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