The goal was the complete modernization of an existing plant producing woven felts for use in the paper industry. The machine consisting of shredder, box feeder, coarse and fine card, and a cross lapper came from the 80s. The lifetime of all components was exceeded and the system had to be brought up to the state of the art.
The machine was disassembled into all individual parts and all wearing parts of the system were replaced. Previously chain-linked movements were decoupled by using single-servo drives. The numerous new engines and gearboxes had to be adapted to the existing plant. All transmissions were rebuilt on timing belts.
It was necessary to replace the complete electrical machine installation, including the control cabinet and operating level. All safety functions were implemented by using a safety control and corresponding drive controllers.
Process optimization and visualization
By means of a visualization specially tailored to the plant, a user-controlled control system as well as an optimal process monitoring of all plant conditions could be realized. By separating the drive technology into 30 synchronously operated servo drives, the flexibility and dynamics of the system has been increased.
The existing operating instructions of the system have been added. New CAD drawings of the plant were created. It was necessary to prepare a risk assessment in accordance with the Machinery Directive.
The numerous measures resulting from the assessment and additional protection devices had to be implemented mechanically and electrically. This increased the safety of the system many times over.