About the customer
Our customer is an engineering company that designs and builds machines and production lines. They manufacture equipment in small series, but also make one-off systems as customised solutions. Projects are completed on a turnkey basis and to the customer’s specifications, based on a design provided by the customer, or a joint design based on the end-user’s set of requirements.
In this project, the end-customer’s product was a semi-finished product that is used for laying playing fields made from artificial grass. In comparison to natural grass, artificial grass systems offer advantages in terms of cost, usability, flexibility and environmental performance. The semi-finished product is delivered on rolls measuring 2500 mm in width and available in various material thicknesses and specific masses. This semi-finished product has to be cut both longitudinally and transversely. Cutting the material produces waste that needs to be removed via a suction system and deposited in disposal bags. During this process, allowance must be made for possible dust concentrations that may result in a fire hazard.
Together with the engineering company, we designed a 4-station roll-to-roll system. The 1st station is an unwinding station where a large roll measuring approximately 2 metres in diameter is unwound at a controlled speed to the 2nd station where longitudinal cutting takes place. This station cuts the product lengthwise in a continuous process. The 3rd station is the transverse cutting station. This is an intermittent movement. A buffer loop is installed between both stations so that they can operate independently of each other. Finally, the material is rewound again at station 4, the winding station. This station uses a continuous process where both force and speed are controlled continuously during winding. The suction system has been integrated in the cutting stations in a way that avoids having to use Atex control components The suction system itself is part of the safety circuit.
Web transportation is controlled by a Lenze servo system, with a master/slave arrangement between the individual servo shafts.
The servo system controls both speed and force and makes continuous corrections based on different feedback signals from buffer loops and diameter measurements.
This engineering company is well aware of our expertise in drive systems. We have already supplied servo-based drive systems to this customer for past projects, which always operated faultlessly. This inspires confidence and, in combination with the high quality and flexibility of our work, creates a good basis for further collaboration.