FEATURE Slitting & Rewinding Giving control to the customer
Universal Converting Equipment continues to grow rapidly using its expertise in control systems to drive the development of slitting, rewinding and related machines that are highly productive, safe and simple to operate
Universal Converting Equipment and parent company, Universal Control Equipment,
has been operating for almost 20 years. Initially formed as a drive and control systems integrator serving the converting industry, the company moved into machine manufacturing 10 years ago. During that time, Universal has seen the benefit of precise machine control linked with ease of use to produce control systems and then machines that have proved very popular with customers and their machine operators. Universal now manufactures a range of slitting and rewinding machines, hot melt adhesive coaters, core cutters, roll handling equipment and other ancillary systems.
The recently launched X6t Dual Turret Slitter is based on Universal’s big seller, the X6
Introducing machine servicing In the last two years, Universal Converting Equipment has doubled its turnover. To support this growth, the company invested in additional manufacturing space, designers and assembly staff, but the business was being held back by the lack of capacity of its sub-contractors to meet their increased demands. In the last year, Universal installed its own machine shop so it could be self-sufficient in machined mechanical parts. This investment plan is now complete following the installation of £1m in CNC controlled machine tools. To reduce product development times, the slitting and rewinding specialist has also invested in the latest CAD/CAM (Computer Aided Design/Computer Aided Manufacturing) systems. When linked to a CAM system, part drawings can be converted into files that can be downloaded directly into the CNC machine tools. This prevents errors caused with manually controlled machines, reduces programming time and eliminates data entry mistakes. The CAM system ensures that consistently high quality components are produced with the minimum of downtime when new designs are entered.
This investment has been designed to support Universal’s growth. From its beginnings as a control system company, it has always been at the forefront of development of drive and control systems for slitting and rewinding machines and
14 May 2015
other converting equipment. Commenting on this growth, Alan Jones, managing director of Universal Converting Equipment says: “Customer’s expect higher levels of quality and productivity from their process equipment. Control systems can make the difference if correctly implemented. It is easy to add complexity to a system. The trick is to make the equipment easy for the operator to use and the engineer to maintain. The complex system sits in the background doing the work.”
Closed Loop Control Systems This means using measuring devices to ensure that the machine is doing what it should be doing. One of the best examples is tension control, using load cells to measure the actual tension of the material. The only way to know and control tension precisely is to measure the tension as you are winding. Complex algorithms are then used to control tensions at the precise level required. All the operator does is enter the tension required and they know that is exactly what they will get time and time again.
Dynamic Circuit Diagrams Most modern control systems are digital and faults can be difficult for engineers to identify. On Universal’s X6 slitting machine, it now has dynamic circuit diagrams on the machine display. These show the status of the inputs and outputs to the system, such
as the tension feedback value from the load cells to the drives. In the event of a problem, the machine can now be checked over in much greater detail without even opening the control panel. The X6 slitter rewinder is Universal’s big
seller. Aimed primarily at the flexible materials market, it is available in widths from 1,000mm up to 2,250mm and speed options of 300m/min up to 1000m/min. It can be configured as a basic machine or with extensive automation features to maximise productivity. Recently, Universal launched the X6T, which has a turret rewind system to minimise downtime between sets of rolls. Dave Ward, technical director, comments: “Although the X6 incorporates a lot of technology, it is based on fundamental design principles - keep the web path as short as possible, use feedback devices to ensure the machine is doing exactly as required, make the structure is rigid so alignment stays perfect and ensure the machine is easy to set up and operate. Load cell tension feedback, automatic knife positioning and core alignment dramatically reduces downtime and increases the time the machine is making money. The X6T uses the same technology but with the addition of a dual turret rewind.”
Universal Converting Equipment T: +44 (0)1473 403333
www.universalconvertingequipment.com
www.convertermag.co.uk
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