Lavorazione di bobine Spagna: processo di ottimizzazione tramite variabilità
Un costruttore leader di apparecchiature per la lavorazione delle bobine ha elimiato inconvenienti legati all’affidabilità e aumentato la velocità della produzione del 300 % incorporanto trasmissioni a velocità variabile fornite da Control Techniques, un’azienda Emerson.
Athader, basato nei pressi di San Sebastian nella Spagna settentrionale, produce linee di fabbricazione di bobine, principalmente linee per taglio longitudinale e linee di livellamento e per lunghezza di taglio per materiali in acciaio, acciaio inox e alluminio. Le apparecchiature prodotte dall'azienda, che fa parte del Gruppo Bradbury, sono destinati a clienti che includono trasformatori per bobine in acciaio, laminatoi e profili e condutture, l'80 per cento dei quali è situati fuori dalla Spagna.
Fino a poco tempo fare, per soddisfare le specifiche del cliente, Athader utilizzata una varietà di marchi per i propri requisiti per la trasmissione. A ogni modo, l'azienda è rimasta insoddisfatta a causa di inconvenienti legati all'affidabilità.
Lo scenario pratico
Quando una linea per la fabbricazione delle bobine subisce un guasto, esiste una probabilità elevata di perdite della produzione per il cliente, oltre che a un danno potenziale delle parti meccaniche. Di conseguenza, Athader preferisce usare trasmissioni, motori e soluzioni globali forniti da Emerson. Secondo l'azienda, poiché una varietà di macchine sono fatte su misura in linea con specifiche necessità del cliente, le soluzioni adattate di Emerson sono fondamentali per il successo dell'azienda.
This is important considering the type of machines manufactured by Athader, such as steel winders/ unwinders, stacking machines, rolling machines, etc., With regard to the latter, a rotary shear device for high thickness coil is expected to work at 100 m/min, while a flying shear system for very high yield stress material (with a high pressure rating of 1100 Mpa) works at 50 m/ min. Despite these elevated speeds, precision must be within ±0.2 mm.
Aside from the high performance and reliability of Unidrive M variable speed drives, Athader says that the products provide impressive speed and response, which in turn allows high dynamic application control with repeatable precision. The intelligent modules used with the drives permit the company to manage comprehensive programs requiring motion in several axes and profiles synchronized with high precision. This involves fast and accurate movements that serve to minimize the number of rejected items and maximize production uptime, all without inducing stress on the mechanical parts. Athader favored the straightforward integration capability of Unidrive M.
Among the recent applications at Athader was the development of a transversal cutting line for steel bands up to 25 mm thick and 1800 mm wide. The Emerson solution includes a control cabinet (8 x 800 x 2200 mm modules) and three control desks (entry, main and exit). The cabinet includes a total of 19 AC drives in a DC bus configuration that ensures stability and optimized energy consumption.
Moving through the cutting line in sequence, the uncoiler is served by a single Unidrive M701 (45 kW) featuring an SI-Application option module and dedicated unwinder software. From here, the unwound coil moves into two levelers, each of which relies on two Undrive M700 units in parallel (180 and 160 kW respectively) with accompanying software. In addition, four Unidrive M200 drives (from 5.5 to 7.5 kW) are deployed for auxiliary elements. The next station, a flying shear, features one Unidrive M700 (110 kW) with Emerson’s dedicated software, along with a single Unidrive M200 (5.5 kW) for the conveyor. In addition, a total of 10 Unidrive M200 drives (from 0.55 to 5.5 kW) control further parts of the system, such as inspection and evacuation conveyors, stackers and stores. The cabinet also features two Emerson SPMC2402 DC rectifiers working in parallel.
The complete line is controlled by a Siemens PLC, while adjustment and supervision is made via a 15" color touchscreen. Two networking configurations are featured: Profinet connects the PLC with drives, encoders and remote I/O, while Ethernet allows the checking and changing of system parameters via a remote PC, including the parameters of the Emerson drives. This capability makes for easy fault-finding and element replacement.
Athader states that working with Emerson’s solutions support has allowed the company to optimize its machine designs. For instance, production speeds have increased by more than 300 per cent, from 200 to 600 m/min for longitudinal systems. In addition, the machines can now process a wider range of materials, from 12 mm band thickness (500 MPa) in the past, to the current 25 mm thick (1100 MPa).
As a result of this evolution, Athader’s latest generation of machines offers a more intuitive environment for the operator. Furthermore, commissioning time has been reduced from 6 weeks to 3-4 weeks, while machine-side and remote control are better facilitated thanks to user-friendly software and Ethernet technologies.
Emphasis on partnership
Before commencing the project, Athader sought a technological partner that would allow the company to progress its development efforts more quickly, which has certainly turned out to be the case. Aside from the high quality of its products and solutions, Athader was attracted to Emerson because of its expertise, proactive attitude, hands-on approach and open collaboration with its technicians.
Moving forward, Athader expects to introduce more products from the Emerson portfolio into its production, including high-efficiency induction motors, high dynamic AC motors and geared motors.