The client in the geotextile industry recently invested in a retrofit of an existing fleece layer: a nonwoven machine – a complex element of the needle felt line. 
The fleece layer is a very complex and dynamic machine. In order to achieve a high-quality product, the membranes have to be placed evenly on top of each other. This requires continuous, controlled movement according to a very precise mathematical model. Most machines are also designed as 'black boxes': only the original manufacturer knows exactly how they are put together.
In addition to increasing efficiency and safeguarding production, 'opening up' the machine was therefore an important requirement for the customer. They want to be able to adapt and optimize themselves as much as possible. 

ATS has thoroughly modernized the fleece layer machine with the latest motion control technology from Siemens.
Co-creation
That is why they flew in on this project in co-creation with the end customer.  To be able to upgrade the machine to the latest technology, ATS and the end customer first had to get a clear picture of how the fleece layer works today. ATS literally started working with pen and paper and the layout of the mechanics. Reverse engineering and testing They were then able to check how the model works today through reverse engineering and testing. That allowed them to make a functional description and determine which components to replace and how exactly they should work together.
Retrofit
Such a retrofit is often a much more cost-effective solution for machines that are still in top mechanical condition. For example, only the motors, cabling and software are replaced. In this case, it is more than enough not only to guarantee production to customers, but also to be future-proof.
ATS equipped the renewed fleece layer with, among other things, the following Siemens components:
- Sinamics S120 drives for high performance applications that require a high degree of precision. These drives also have a common DC circuit, which allows them to recover braking energy from the various axes. The modular construction provides additional flexibility for repairs and replacements.   - Simotics S servo motors with a high torque range and optimal integration with Sinamics S120.   - Simatic S7-1500 T-CPU: the technology controller for demanding applications that excels in user-friendliness and flexibility. 
 
The new S7-1500 T-CPU: the 'brain' of the machine, allows an even higher degree of integration and is also very user-friendly. In this way, the customer has a lot of pre-programmed motion control functions, without the need for far-reaching expertise. This controller is also capable of taking over complex calculations from the drive, making the latter even more responsive and accurate. In a fleece layer with 5 axes that have to work perfectly synchronously by means of a camming function, that is no superfluous luxury.

From black box to openness and efficiency: ATS makes fleece layer future-proof