MONITORING AND CONTROLLING OF WIRE TENSION · PDF fileStrand Tension Control –Target ... •Total weight of a 1’000mm test piece from running production ... Norbert Schilling Created

MONITORING AND CONTROLLING OF WIRE TENSION ON STRANDING AND SIMILAR ROTATING PROCESS MACHINERY

CabWire Industry Forum, Düsseldorf, November 2017

Norbert Schilling, Product Manager

Today’s Challenges for Producers

Price / cost pressure

• Production speed

• Throughput

Increasing quality requirements

from the market

• Lack of technology / tools to

capture appropriate data

• Difficult to keep processes stable

on a high quality level

Page 2

FMS for CabWIRE Conference

November 2017

Efficiency – of installed, aged machinery

Extend Lifetime of Rotating Equipment

Page 3


November 2017

Retrofits, Upgrades Regardless of End Product

Strand Tension Control – Today

Tension measurement

• None, manual, mechanically,…

Rating of the “measuring values”

• None, subjective judgement depending

on operator

Adjustment / control options

• None, manual, semi automatic

(simple mechanical solutions)

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November 2017

No / poor solutions

VARIOUS SOURCES OF ERROR

Strand Tension Control – Target

Tension measurement

• Fully automatic and continuous

• Precise and reliable

• Flexible, adaptable to different products

Judgment / rating of the measuring values

• Objective, repeatable

Adjustment

• Fully automatic or manual

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November 2017

Easy to Retrofit, Full Flexibility

Easy Retrofit – Basic Requirements

Various machine types and sizes

• Cage type stranders

• Tubular stranders

No sliprings

• Battery powered (long battery life)

Wide range of wire/strand tension

Simplicity (installation, operation)

Interface to PLC

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November 2017

Reliability and Cost Effectiveness

Modular System with Closed-Loop Control Function

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November 2017

Tension Measurement

Data Transmission

Monitoring, Processing,

logging and recipe managerBrake Control

Telemetry System – Tension Measurement

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November 2017

Telemetry System RTM X42 – Tension Monitoring

Clear visualization of measuring values

• Configurable screens

Indication and parametrization of reference and threshold values

Data logging

Page 9


November 2017

Telemetry System RTM X42 –

Recipe Manager and Quality Reports

Recipe Manager

• Management of process

values

• Reference values

• Threshold values

• Alarm settings

Quality Report Manager

• Data logging

• Protocols

Page 10


November 2017

Telemetry System RTM X42 – Tension Control

Page 11


November 2017

Case Study (Germany)

Compound cable

• Small diameter steel tubes with inserted fiber optic cables

• Aluminum strands

• Ground wire for high-voltage power lines

– 20’000 phone calls per optical fiber

at a time

Actual situation

• Manual tension monitoring &

control of all “strands”

• No parameters available for

quality and process control

• Fluctuating product quality

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November 2017

Case Study (Germany) – Challenge

Stable stranding process for steel tubes with inserted fiber optic

cables

• Avoid any tension stress on fiber optic cables

• Provide excess length of the fiber optics within the tube to allow

winding/unwinding and cable swinging (caused by wind)

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November 2017

Aluminum wire Steel tubeAluminum wireSteel tube

Case Study (Germany)

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November 2017

Downtime (for re-adjustment of brakes):- 1.5hrs

Strand tension tolerance: x 2.8

Throughput: + 19%

Manual Control

Closed-Loop

Case Study “High Voltage Power Cable” (USA)

Rigid strander

• 3 sections, with 12 strands each

• Cable cross section 1’200mm2

“Visual” tension measurement

• “…observation of wire vibration upstream

to the stranding point…”

Quality control

• Total weight of a 1’000mm test piece

from running production

Page 15


November 2017


Pneumatic brake system for each machine section

• Brake tension adjustment only per section

• No tension control of individual strands

• Extensive service/maintenance costs

for pressure air equipment

– Pressure air tanks

– Compressors (1 standy-by required)

– Pressure lines

• Frequent downtimes to refill the tanks

Page 16


November 2017

CUSTOMERS DEMAND – “SUBSTITUTE PNEUMATIC BRAKES”


Step 1 - Remotely controlled brakes w/o tension monitoring

• Complete substitution of “costly” pneumatic equipment

• Dramatically reduced downtimes

– Reduce maintenance costs (for pneumatics) 70%

– Reduce downtimes (charging of pneum. Tanks) 25% of total uptime

Step 2 – Implement tension monitoring with closed-loop control

• Targets

– Reduction of material used min. 2% of throughput

– Another reduction of downtime 15% of total uptime

– Estimated ROI of monitoring and control system 0.75 year

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November 2017

ONGOING PROJECT

Summary

Tension Measurement (Retrofit)

• Quality improvement with objective wire tension measurement

Tension Monitoring

• Increased process safety with recipe manager for repeatable

production parameters

Tension Control

• Higher efficiency with continuous control and uniterrupted

production

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November 2017

Measurement / indication of wire tension – instead of guessing + easy retrofit

Seamless Quality Documentation – as additional tool for implemented quality control

Continuous Control – instead of production stoppages

FMS Telemetry Systems – Worldwide Reference

Page 19


November 2017

FMS Telemetry Systems

Page 20


November 2017

Tension

Measurement

Telemetry System RTM X42 Flexible Tension

Monitoring & Control

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November 2017

Tension

Monitoring

Tension

Control

For Rotating Applications

Designed to compensate centrifugal and coriolis forces

Flat and compact design, made for wire & cable machinery

Covering entire range of required nominal forces

Page 23

050 Tension Measurement and Control for Wire&Cable.pptx

December 2016

RMGZ100B RMGZ400 RMGZ800RMGZ200 RMGZ300B RMGZ900 mini

FORCE SENSOR ALIGNMENT

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December 2016

Red dot in direction of resulting force

Force Sensor Alignment in Static Applications

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December 2016

Red dot and sensor axis parallel to rotation axis (RMGZ)

Force Sensor Alignment in Rotating Applications

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December 2016

Force Measuring Rollers for

Precise Measuring Results

Point of measurement matches the point where the force is

applied

No mismatch by leverage

effects

No (very little) influence

of the occurring

coriolis forces in rotating

applications

Page 27

060 Telemetry Systems

May 2015

Configuration

Page 28


May 2015

Telemetry Systems – Variations

Variation Systems No of Channels

RTM X42.MODBUS 35 258

RTM X42.IO 11 54

RTM X42.MODBUS.PC 5 60

RTM X42.PC 14 218

TOTAL 65 590

Page 29


May 2015

Functional Description –

RTM MP Radio-Based Data Transmission

Page 30


May 2015

Content – 35 Min., incl. Q&A

• IST 2

– Installed base vs. new machines, stranding process today

– No (basic, manual) tension monitoring, manual tension control

– Quality issues and alternating process safety

• SOLL 3

– Automated, continuous monitoring (and control) for high quality products

• ANGEBOT 3

– RTM X42: 3 modules from monitoring to full quality control

• BEWEIS 5

– Case studies AFL, Encore Wire (anonymous)

• ABSCHLUSS 3

– References, difficult times, large variety of products

– Demo unit with all components available

Page 31


November 2017

Documents

MONITORING AND CONTROLLING OF WIRE TENSION · PDF fileStrand Tension Control –Target ... •Total weight of a 1’000mm test piece from running production ... Norbert Schilling Created