The upgrade has resulted in the Coating Line being significantly more efficient and notably easier to operate.
A complete upgrade was designed and implemented, which involved the following:
- ATEX-Rated Permanent Magnet Servo Motors: The replacement of DC motors with ATEX-rated permanent magnet servo motors significantly improved energy efficiency and control precision.
- SINAMICS Active Front End (AFE): By integrating Sinamics AFE, the system achieved a near-unity power factor, reducing reactive power and overall energy consumption.
- Full PROFISAFE Integration: The machine was equipped with a full PROFISAFE solution that incorporated safe speed monitoring, improving operational safety and reducing risks during maintenance and production changes.
Results and BenefitsFollowing the upgrade, the machine achieved several substantial improvements, making it the most energy-efficient unit in the factory, even outperforming newer equipment. Key benefits included:
- Enhanced Energy Efficiency: The new servo motors and optimized drive system minimized energy waste, eliminating the need for ventilation or purging, which reduced fan energy consumption.
- Increased Production Speed: The upgraded machine operates at a higher production speed without compromising product quality, resulting in improved throughput.
- Reduced Maintenance Requirements: The new configuration eliminated the need for regular recalibration, easing the workload on maintenance staff.
- Improved Operator Satisfaction: Operators appreciated the simplified “one-touch” start functionality, which made operation straightforward and reduced the likelihood of errors.
- Minimized Product Losses: By eliminating web breaks and improving coating consistency, the machine reduced material waste and product rework.
This comprehensive machine upgrade resulted in a safer, more energy-efficient, and flexible production process, meeting the customer’s needs for reliability, flexibility, and operational efficiency. With improved equipment uptime, increased production speed, and lower energy costs, the customer has a future-proofed machine that supports long-term productivity and cost savings.
