Fiber optic extrusion line

Uncoilers must continuously and reliably exchange information with the pre-existing extrusion line.

Each individual uncoiler is a small quasi-machine with its own operating logic that adjusts the position of a dancer, which has the peculiarity of having little accumulation and therefore a certain criticality in adjustment. Each group of 6 decoilers is controlled by a unique activation/deactivation, as is each decoiler (which groups 24 cantres). This allows the operator a quick setup of the line, which can be used with flexibility of use in a wide variety of configurations (e.g., 24 reels, 48, 96) or quickly change a processing so as to reduce setup time.

The pre-existing line also manages the general safeties of the system, and the use of safety CPUs was chosen for streamlined and reliable management of safety signals to each individual unwinder. The use of a communication bus that supports safety communication makes sure to reduce the wiring and thus speed up the installation of the system, but most importantly, it increases the reliability of the overall system by reducing the connection points and thus the possibility of failure.

The management of dancer signals and activation logic is done locally, thus relieving CPUs of computation, making the reaction of dancer management fast and effective. Upon activation, the dancer moves gradually to the chosen processing point so as not to subject the optical fiber to any abnormal stress or strain.

Each dancer has a fiber break detection system, an alarm that is communicated to the main line and then shown to the operator, who will choose the appropriate reaction (e.g., stop the line or continue production with downgrading of the product).

Uncoilers can work with quite a wide range of pulls, from a few tens of grams to several hundreds, thanks to precise, low-friction realization of all rotating axes involved. Uncoilers can work at up to more than 1000 m/’, where each individual coil can be set in motion and accelerated to production speeds in a matter of moments, thanks to special management of the PID that governs the dancers.

Experience in making similar machinery has enabled quick and effective testing and commissioning to the satisfaction of the end customer.

The design phase of the project involved 3 months‘ work.

The commissioning process of the plant, which we took care of in all details, lasted 1 month, providing the customer with a tested plant that complies with production needs.