Outdated equipment and the need for increased cutting accuracy at varying speeds have prompted the upgrade of a flying shear system at an automotive accessories plant, where the company manufactures exhaust systems for various makes of automobile.
The latest EcoDrive 03 range of servo drive from Tectra Automation
"There are two inter-linked aspects of this project that made it quite amazing - the fact that we had an off-the-shelf solution available to satisfy the client's requirements, and the speed of implementation," says Tectra Automation's technical manager, Georg Venter. "As a result of having a standard package available, we were able to install the system comprising a control unit, HMI and servo drive in just two days!"
The application in question is a cut-to-length system of exhaust pipe components. This cut-to-length happens 'on the fly' at 150 cuts per minute. High levels of accuracy, repeatability and the power to function at high speeds over extended periods of time. It employs one motor to drive a planetary, in-line gearbox, connected to a rack and pinion that drives the cutter mechanism back and forth. Following the successful installation of Tectra Automation's Indramat solution, volumes of metal processed by the system increased from 9 km per shift to 27 km per shift. This came as a direct result of the new components being able to cut very accurately at speeds of up to 2,5 m/s.
"An important improvement on the previous system can be found in the fact that our solution does not require any adjustments for cutting at varying speeds," Venter points out. "Previously, an operator had to make certain changes to the machine set-up before allowing material to flow through at a different speed. Now, the process can continue at whatever pace is required, no matter how many times the speed of material flow changes. Further flexibility has been engineered through the ability to change material sizes on the run. The system was also configured to be Profibus compatible."
The hardware
Tectra's standard solution includes a CLM 1.4 control unit, a 200 A Ecodrive servo solution with a peak torque of 187 Nm, and a BTV human machine interface. Using existing optical equipment from the customer, the new solution is also able to detect predetermined painted lines on the material and actually cuts along these marks.
"I am confident that we will be awarded two similar projects by this client in the near future, based on the improvements that translated from our speedy and inexpensive solution," Venter enthuses. "Although the system is virtually maintenance free, our local branch in the area will be available for any support requirements that may arise."
For more information contact Georg Venter, technical manager, Tectra Automation, +27 (0) 11 971 9400, [email protected], www.tectra.co.za
Monitoring vibration allows for equipment longevity Iritron
Other technologies
Unscheduled downtime and maintenance on machines is often a source of frustration for many companies active in industrial manufacturing as it results in loss of process and productivity, which in turn equates to loss of revenue.
Read more...Building resilience in extreme environments
Other technologies
The petrochemical and oil and gas sectors operate in unforgiving environments. In this high-stakes industry, operational efficiency is vital, and unplanned downtime can have severe consequences. To thrive in this demanding landscape, a proactive and sophisticated approach to maintenance is no longer an option, but a necessity.
Read more...Extending oil drain intervals
Other technologies
In a recent field study, African Group Lubricants tested the performance of Mobil Delvac Modern MX 15W-40 Super Defense engine oil under rigorous operational conditions. The goal was to extend the oil drain interval while maintaining optimal engine performance and reliability.
Read more...Latest advance in automotive cooling fluids
Other technologies
The automotive industry is undergoing a significant transformation, driven by advancements in vehicle design and increasing demands for enhanced performance and durability. These changes are bringing a marked shift toward formulations that offer improved heat dissipation and robust corrosion resistance.
Read more...Advancements in wire rope testing
Other technologies
Being able to get instant, real-time and portable detection of wire rope flaws can make a significant difference for operational teams. There have been a number of significant technological advancements and tools entering the market that help wire rope operators detect and resolve problems faster.
Read more...Complete solutions for the die casting industry
Other technologies
Die casting is a manufacturing process that involves injecting molten metal into a mould to produce complex, high-precision components. FUCHS Lubricants South Africa addresses the evolving demands of the die casting sector through continuous product innovation and development.
Read more...Rethinking common approaches to wire rope lubrication
Other technologies
: Wire ropes are hard-working components in many different applications, from mines to lifts, ports, construction sites and drainage systems. Correct lubrication of wire ropes is absolutely critical because wire ropes are more than just cables, they are intricate machines composed of interdependent parts in constant motion.
Read more...Quantum refrigerator paves way for reliable quantum computers
Other technologies
Quantum computers require extreme cooling to perform reliable calculations. Researchers at Chalmers University of Technology, Sweden, and the University of Maryland, USA, have engineered a new type of refrigerator that can autonomously cool superconducting qubits to record low temperatures, paving the way for more reliable quantum computation.
printer friendly version