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Fabric production

Fabric-production_groß

Fabric preparation

Yarn finishing and handling machines perform tasks such as twisting (for thicker and more robust yarn), texturing (for changing the yarn surface) and winding onto bobbins. Precise motion control is the most important quality factor and has a strong impact on subsequent processes.

Winding is a particularly sensitive process with regard to the mechanical properties of the fibers. If stretched too much, weak points can break easily. For such situations, B&R offers an out-of-the-box solution to ensure that the rolling cylinders apply the correct tension to the fiber. Perfect closed-loop torque control and compensation of mass inertia are embedded in ready-to-use libraries.

Weaving

Weaving is a textile process that has evolved quite a lot since it was first invented to create the grid of fibers that composes the fabric. As market demand increases, the speed of weaving and its efficiency must also increase to gain in productivity. B&R is able to support the highest levels of weft insertion performance. The possibility to configure drum sequencers for relay nozzles and to integrate auxiliary devices is also a great advantage, helping production adapt flexibly to different recipes and materials.

Knitting and warp knitting

The knitting process creates fabric from a thread or yarn by making consecutive rows of loops that are interlocked together. Although there is a wide range of methods for each stitch, all of them need to be extremely precise and fast. B&R can provide all the necessary technology to fit specific machine requirements such as electronic needle selection or technology for circular knitting machines.

Non-woven production

Non-wovens can be produced by carding, spunbonding and melt-blowing. Each manufacturing process gives the web different properties. For all of them, however, perfect automation influences the quality of the material.

B&R has the perfect solution for...

Winding

Winding control is one of the most critical parts of every machine that needs to handle rollers accumulating or releasing material. The simultaneous control of torque, speed and axis synchronization is among the most challenging tasks in automation, but with B&R technology it fits seamlessly into the overall solution. Profit from our automation and control expertise in the areas of:

  • Surface winders
  • Central winders
  • Direct winder drives using torque motors
  • Axis synchronization
  • Dancer control
  • Tension control
  • Automatic roller changes 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. The intelligent solutions from B&R prevent production wastage and eliminate the time-consuming process of getting the plant up and running again after a power failure.

Enhance efficiency with linear motors

A considerably more efficient alternative to the pneumatic cylinder is a linear motor, which uses electromagnetic forces to convert electrical energy directly into movement. A convenient side effect of linear motors is that, since they lack fluid components, they are much easier to install. This is especially relevant in cases where short linear movements are the only aspect of the machine that use pneumatics.

Like all electric motors, linear motors are extremely efficient by nature. This fundamental efficiency can be further increased using advanced drive technology such as ACOPOS servo drives from B&R, which can store braking energy in a DC bus circuit to be used for later acceleration. It is also relatively simple to return excess energy back into the power grid.

Maximum motion control 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 profile transitions that today's high-speed machines require. With no programming, the drive compensates for cam profile 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 motion profiles – without significant additional effort in 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 with options that can easily satisfy the requirements of the end user.

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-rated 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 Generic Motion Control (GMC) concept allows the software to be developed independently of the motor type. 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 multiple temperature zones
  • Storage space for large amounts of data

And of course complete integration into the system goes without saying.

Synchronization in real time

With POWERLINK, B&R achieves real-time synchronization even in decentralized systems. Controllers and distributed I/O run synchronously with a precision <100 ns. With weaving machines and different methods of weft insertion, for example, the elimination of specialized hardware means that speeds can be significantly increased with high processing quality and reduced costs.

Go back to overview or see General solutions for the textile industry.

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