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Fabric preparation

Yarn finishing and handling machines perform tasks such as twisting (for thicker and more robust yarns), structuring (to change the yarn surface) and winding on bobbins. Precise motion control technology is the most important quality factor and strongly influences subsequent processes.

Rewinding is a particularly sensitive process with regard to the mechanical properties of the fibers. If the tension is too high, weak points can easily break. B&R has out-of-the-box solutions for such situations that ensure the correct tensile stress on the textile fibers. Perfect control and compensation of mass inertia are integrated in ready-to-use libraries.

Weaving

Weaving, where fabric is created from a net of fibers, has developed much further as a textile process since it was first invented. As market demands increase, web speed and efficiency must also be increased in order to increase productivity. B&R can achieve maximum performance when inserting the weft yarn. The possibility to configure rollers for relay nozzles and integrate auxiliary devices also offers major advantages. This means that production can be flexibly adapted to different fabrics and materials.

Knitting and warp knitting

With knitting, a fabric is formed from a thread or yarn by interlacing successive rows of loops. There are different methods for each stitch, but what they all have in common is that they must be performed extremely precisely and quickly. B&R technologies allow specific machine requirements such as electronic needle selection or circular knitting machines to be implemented.

Production of nonwoven material

Nonwoven material can be produced using carding, spinning and melt blowing methods. Each manufacturing process gives the fabric different properties. Perfect automation solutions, however, affects material quality with all of them.

B&R has the perfect solution for...

Wrapping

Wrapping control is one of the most critical parts of machines where rolls of material are accumulated or released. Simultaneous control of torque, speed and axis synchronization is one of the most challenging tasks in automation. Thanks to B&R technology, however, this can be seamlessly integrated into the overall solution. Benefit of our automation and control expertise in these areas:

  • Surface winder
  • Center winder
  • Direct winding drives using torque motors
  • Axis synchronisation
  • Dancer control
  • Tension control
  • Automatic reel change at full line speed
Save time and resources with intelligent incident reaction

The intelligent B&R ACOPOSmulti motion control system automatically detects dips in the primary power supply and initiates an emergency shutdown. The kinetic energy that remains in the motors is used to maintain automation functionality until the system reaches a complete stop. The ACOPOSmulti's active power supply module generates 24 VDC for the controllers, I/O modules and drives – eliminating the need for a UPS. B&R's intelligent solution prevents waste during production. Restarting the the production system after a power failure, which can be a length process, is also not necessary.

Improving efficiency with linear motors

Linear motors are a significantly more energy-efficient alternative to pneumatic cylinders, where electrical energy is directly converted into motion via electromagnetic force. A positive side effect of linear motors is significantly simpler installation because fluid components are no longer required. This aspect is particularly important when short linear movements are the only way pneumatics are used on the machine.

Like all electric motors, linear motors have a very high efficiency. This can be further increased if modern drive technology, such as ACOPOS servo drives from B&R, is implemented. They can also store the braking energy in a DC bus circuit and make it available for later acceleration processes. Excess energy can also easily be fed back into the grid.

Drive solution with maximum performance

With the real-time Ethernet POWERLINK protocol and B&R's comprehensive range of motion control solutions, optimizing production lines is virtually effortless. B&R allows you to simultaneously boost both quality and productivity.

With a communication cycle of 400 µs and a current control loop of 50 µs, the ACOPOS series provides the extremely fast, event-based cam transitions that today's high-speed machines need. With no programming whatsoever, the drive compensates for cam deviations every 400 µs. This outstanding performance is completely independent of how powerful the controller is or how many real or virtual axes are used in the application.

The touch probe inputs on the ACOPOS series are processed in the sub-microsecond range and are perfectly suited for applications such as rotary or fly cutting and quality control. This speed makes it possible to react in real time and perform smoother transitions between movement profiles without significantly impacting software development.

Compact and flexible motor and drive systems for modular machinery

B&R offers hardware and software solutions for fast and easy development of mechatronic machines that implement end customer requirements as equipment options:

Scalable drives and motors with a small footprint include:

  • Servo motors with an integrated drive: ACOPOSmotor
  • Servo motors with a distributed IP67 drive: ACOPOSremote
  • IP67 and IP20 certifiied I/O, optional safety modules: X20, X67 I/O modules
  • Stepper motors: 80MP and ACOPOSmicro

B&R offers machine builders a comprehensive selection of motor types. The software is developed independently of the motor technology being used. the GMC concept (Generic Motion Control) makes this possible. That means, once programed, the GMC it works for every motor, drive or other mechatronic module in your machine. Thus, you can save time and resources and at the same time choose freely the solution that best fits your requirements.

Temperature control

An extensive temperature control library with function blocks, PID controllers and HMI templates is the ideal solution for systems that require precise control of heating and cooling.

The library supports:

  • Autotuning
  • Management of several different temperature zones
  • Storage space for large amounts of data

Complete integration within the system is of course also ensured.

Synchronization in real time

With POWERLINK, B&R achieves real-time synchronization for remote systems as well. Controllers and remote I/O run synchronously with a precision <100 ns. For weaving machines with different weft insertion methods, for example, the elimination of special hardware means that it is possible for speed to be significantly increased while processing quality remains high and costs are reduced.

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