At Provide Solution, our commitment is always focused on finding innovative solutions that enhance production efficiency and ensure maximum precision. A significant example of this dedication is our recent collaboration with B&R, which resulted in an ambitious and cutting-edge project: the winding machine for the production of carbon tubes.
Advanced Hardware Configuration
For the winding machine project, we selected state-of-the-art hardware components to ensure high performance and reliability. The configuration includes the following elements:
- B&R X20CP1686X functional PLC: equipped with digital and analogue input/output modules for precise and versatile control of operations.
- B&R X20SL8100 safety PLC: integrated with safety input/output modules to ensure operational safety at every stage of the production process.
- Acopos with integrated Safemotion: five models are used, from one to three motors, to manage the machine’s complex movements.
- 12 B&R motors: to ensure smooth and precise handling of all winding and material movement processes.
Utilised Mapp Functions
B&R’s Mapp functions allowed us to create a highly customisable and easy-to-manage machine, thanks to the following features:
- MpRecipeXml: for creating and managing machine recipes, allowing quick and flexible configuration of processing parameters.
- MpAlarmXCore: for managing machine alarms, ensuring constant monitoring and quick responses to potential issues.
- MpAlarmXHistory: to maintain a history of the machine’s alarms, facilitating the analysis and resolution of recurring problems.
- MpUserX: for managing user access and authorisation levels, ensuring only authorised personnel can modify critical parameters.
- MpDatabaseCore: for communicating with an SQL database, useful for saving reports and recipes, allowing full traceability and optimal management of information.
- MpAxisBasic: for managing axes and their respective functions, ensuring precise and coordinated movements.
- MappView: for creating a simple and intuitive user interface, enhancing the operator’s interaction with the machine.
Other Implemented Functions
We integrated communication and file sharing via OPC-UA, creating a highly efficient Industry 4.0 system. With MpAxisBasic, we enabled advanced features such as coupling for axis synchronisation, cyclic for cyclical management of speed and position, and CAMsequencer and CAMprofiler for cam generation to control axis movements.
Machine Operation
The winding machine is designed to handle various complex and precise processing stages, including:
- Carbon tape winding: around a mould at precise angles and steps, creating a uniform and durable base for the carbon tube.
- Winding of woven carbon sheets: around the mould to complete and reinforce the tube, ensuring maximum structural strength.
- Thermal tape winding: around the tube to eliminate air bubbles before oven curing, ensuring a flawless, perfect finish.
- Creation of woven carbon sheets: used to replace some of the processes described, offering flexible and optimised alternatives based on specific production needs.
Client Benefits
- Precision and Reliability: The winding machine is designed to ensure a high level of precision and reliability, minimising errors and improving the quality of the final product.
- Production Efficiency: Thanks to the integration of advanced hardware components and Mapp functions, the machine ensures efficient and fast production, reducing downtime and increasing productivity.
- Flexibility and Customisation: The Mapp functions and modular configuration allow for easy and quick customisation of the machine, adapting to the specific production needs of clients.
- Operational Safety: The integration of safety PLC and Safemotion functions ensures a safe working environment for operators, reducing the risk of accidents.
The winding machine for carbon tube production is a perfect example of our ability to integrate advanced solutions to improve productivity and precision. Our collaboration with B&R has enabled us to develop a system that meets the most complex needs of our clients, while also offering flexibility and modularity. We will continue to innovate to keep our clients at the forefront of Industry 4.0.