Upgrade & Retrofit Solutions ATLAS Slitter Rewinders · years, the machine control systems on many...

Upgrade & Retrofit Solutions

ATLAS Slitter Rewinders

Improving quality & productivity

Atlas Converting Equipment Ltd. has beenmanufacturing slitter rewinders since 1976and Titan slitter rewinders were firstintroduced in 1964.

Consequently, in almost 50 years more than1,000 Atlas and 2,500 Titan slitter rewinders havebeen installed in over 70 countries worldwide.

Most are still in operation but slitting & rewindingtechnology has advanced dramatically over theyears, leaving the older machines to be much lessproductive. Not to mention how much moresophisticated the range of materials has becomefor slitting, especially for flexible packaging andplastic film production.

“We are very pleased with the work completedby Atlas on our 16 year old CW960 primaryfilm slitter. This has made a considerabledifference to our film slitting productivity,which means we have many more satisfiedcustomers.”

Mr. Heung Yeon Kim, Technical Director Youl Chon Chemical Co. Ltd., Seoul, South Korea

Providing the solution

Atlas is pleased to provide its customers with adedicated service for upgrading the specificationof older slitter rewinders to help increaseproductivity, reduce waste and improve thequality of the finished reels processed. All ofwhich should help to improve the profitability ofconverters’ business operations.

Improved web tension control, replacement ofobsolete components and retro-fitting the latestcomputer hardware & software systems are justsome examples of how Atlas & Titan can supportthe future business of its customers.

Other examples of cost-effective upgrades andretrofit solutions for Atlas slitter rewinders are:-

• Machine Control Systems

• Rewind Arms

• Rewind Arm & Knife Positioning

Systems

• Replacement Drives

• Contact Rolls

• Pneumatic & Hydraulic Upgrades

02 www.atlasconverting.com/upgrades

Machine Controls

This upgrade package is tailored tomeet specific machine requirements.The S7 PLC has Ethernet support whichenables access of production data tothird party systems.

The PLC upgrade replaces the S5system including the rack mounted I/Osystems. Machines with obsoleteremote ET200B I/O systems can bereplaced with the latest I/O systems.

With the constant advance ofcomputer technology over theyears, the machine control systemson many older models of Atlasslitter rewinders have becomeobsolete but can be replaced withthe latest computer hardware &software.

New systems use a Windows platformfor the operator interface with touchscreen control. Older PLC systems canbe replaced with Siemens S7 systemsgiving good control using the latestwinding software.

These two solutions combined offer avery stable system which is easilysupported by Atlas technicians.

Analogue cards for PID control,transducer drivers, etc will beredundant when the function of theseis moved to the PLC.

The operational screens have a fulldiagnostics capability enabling theoperator or technician to quicklydiagnose problems.

Remote diagnostics Internet protocolmodems are fitted which can be usedto diagnose faults (also requires anoptional maintenance contract).

Main operator screenUpgraded machine control panel

Upgraded PLC

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• Obsolescence• Replacement of analogue cards• Orientation problems

• Rewind arm positioning• Rewind arm cables• Knife positioning system• S5 PLC replacements

The effective solution for resolving:

Associated upgrades

Features

• Touch screen interface• No key pad• Replaces obsolete hardware

Benefits

• Easy maintenance• Improved set-up flexibility• Enhanced control functions• Ease of use

Increased rewind diameter capacity

Rewind arm belt drive

For many years, the rewind armson all Atlas slitter rewinders were arobust and reliable solution forprocessing a wide range of plasticfilms, labelstock, paper and board.

However, the range and specificationof various materials has improved andincreased since many machines werecommissioned and different productionrequirements are now needed.

The vastly improved specification of thenew style rewind arms provides a moreaccurate and much better quality ofwinding. Productivity will be increasedwhich will also help profitability.

Rewind Arms


Some of the improvements include:

- revised bearing head arrangements for higher weight reel capacity up to 5,000kg per rewind station;

- drive gear replacements with belt drive to improve tension control at lower ranges;

- arm cables to reduce the number of stoppages due to cable failure;

- mechanical fail safe locks to prevent the rewind arms moving during operation and to increase safety.

There are other various optionsavailable including heavy duty rewindarms for larger rewind diameters andnon-driven chucks for low tensioncontrol.

Associated upgrades

Features

Benefits

• Improved rewinding quality• Increased productivity• Higher production capacity

• Contact roll enhancements• Replacement drives• E/P transducer• Hydraulic control• Rewind arm cables

• Larger rewind reel diameters• Increased loading capacity• Optional AC control

• Low productivity• Prolonged machine downtime• Production capacity• Poor winding quality


Combination rewind arm

Rewind Arm & Knife Positioning Systems

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• Obsolescence• Prolonged machine downtime• Low machine productivity

• PLC and PC hardware• Siemens S7 & Windows™ required• Rewind arm positioning


Associated upgrades

Features

• Replacement of obsolete components - Smart Drive - SA14 - Servo node 50

Benefits

• Ease of operator use• Large PDF storage• Clear diagnostics

The rewind motors can be moved in toany position with a switched addressingsystem which avoids the need toprogramme devices when motors areexchanged.

The system is flexible and enables theoperator to place slit patterns whererequired rather than in fixed positions.

The controller uses the latestEthernet/CAN protocols forcommunication. This decreasescommunication errors caused byelectrical noise and ensures that thecontrol system is robust enough towork in demanding environments.

Atlas has developed a standard solutionfor the replacement of obsolete systemswith the latest technology to improveperformance and productivity.

The operator screen has improveddiagnostics to help the operator withproblems in knife and rewind armpositioning. It also has a full diagnosticscreen which enables technicians toquickly diagnose faults.

The knife positioning systems use thesame type of motor but with adifferent frame size to the rewind armpositioning systems. Each motor has adrive module built-in to reduceconnections and increase reliability.

In some cases, the positioningsystems on Atlas primary slitterrewinders have been in operationfor more than 20 years and arenow considered to be obsoletetechnology.

Rewind arm positioning system

Razor knife positioning system

Positioning set-up screen

This upgrade replaces obsoletedrives with current, tried and testeddrive technology.

The Atlas drive is a PWM technologywhich has been specifically designedfor permanent magnet motors. The DCdrive is a rack mounted device whichsuits all of the rewind motors used inthis configuration, by using a simplepersonality card.

On machines with an older Infranorrack system the Atlas drive system willfit directly in to position. Slitterrewinders with individual rewind driveswill be removed and the new racks willfit in place of the older units.

Other options are available for the edgetrim spooler drives. These can also beconverted to AC providing a muchbetter control of the pull roll speeds.

On many of the Atlas primary filmslitters there have been improvementsto the harmonic gear box which canextend the life of the unit.

The harmonic gear box can be added tomany of the CSE range of secondaryslitters providing a solution to windingproblems when using difficult andspecialised films.

Siemens AC drive

Atlas 0808 DC auxilliary drives

The new rack systems are easilymaintained with the calibration on thepersonality card. If a drive should failthen it can be replaced in moments bychanging the personality card.

AC drive upgrades are available toreplace the DC web drives and DCrewind drives. The replacement ACdrives are available for most of theAtlas range of slitter rewinders.

Using brushless technology and resolverfeedback they require very lowmaintenance and are very efficient.

Atlas 3021 DC rewind drives

Replacement Drives


Associated upgrades

Features

Benefits

• Harmonic drives• Rewind arm refurbishments• Rewind arm cable replacements• PLC and PC hardware

• Standard Atlas developed drive• Compatible with existing motors• Replaces obsolete drives• AC drives an option

• Improved reliability• Reduced downtime• Less maintenance

• Expensive rewind drives• Obsolete rewind drives

- Infranor M59 - Seidel 4KS - SCR Technology


Over the years, Atlas has mademany important improvementsto its range of slitter rewinders.

One of these has been the contactroll clamping mechanism. Thisreduces the change-over timeswhich leads to increases inproductivity.

All slitter rewinders requirecompressed air to assist thewinding control of the rewindreels. This is supplied from acentral compressor and can beexpensive.

Contact Rolls Pneumatic and Hydraulic Upgrades

• Operator fatigue• Poor winding quality• Slow running of machine

• Pneumatic cylinders• Pneumatic manifold• E/P transducers


Associated upgrades

Features

• Rapid product change over times• No tools required by operator

Benefits

• Improved winding quality• Less damage to contact roll

• Poor winding quality• Slow running of machine

• Contact rollers• Dancer roll control


Associated upgrades

Features

• Standard parts• Easy maintenance

Benefits

• Improved winding quality• Less air leaks and waste• Improved diagnostics• Reduced air supply costs

A number of improvements have beenmade to the pneumatic and hydraulicsystems on Atlas slitter rewinders.These include new style E/P transducerswhich use closed loop PWM controland require very little maintenance orcalibration.

Another major upgrade is changing theair manifold system to a single unitmounted between the internal andexternal rewind sections using spiral PUpipes. This reduces leaks and the setup time for contact rolls.

The hydraulic proportional valve hasbecome obsolete on older Atlas slitters.These units used an analogue card toconvert the signals to drive the valveand require constant calibration.

The new unit is a digital amplifierwithout a separate card. This improvesboth the beam control and rewindingquality.

It also makes the slitter operator’s jobeasier and more productive, with notools required.

Another improvement is the use offloating bearings at the ends of thecontact roll.

This enables the contact roll to find itsown level with the rewind reel providingbetter contact control and avoids theoperator making manual adjustments tothe roll when offset. It also avoids theneed for tie bars between contact rollarms.

Both of these innovations provideimproved production quality and reducedwaste.

Quick release contact roll clamping mechanism

Contact roll pneumatic manifold

If air leaks occur on older slitters itcan be a costly waste and affectthe control of air pressure leadingto poor rewinding quality.

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EuropeAtlas Converting Equipment Ltd.8 Wolseley Road, Woburn Road Industrial EstateKempstonBedford MK42 7XT United Kingdom

T: +44 1234 852553F: +44 1234 [email protected]@atlasconverting.com

AmericaAtlas Converting North America, Inc.9801-F Southern Pine BoulevardCharlotte, NC 28273United States of America

T: +1 704 587 2450F: +1 704 587 [email protected]@atlasconverting.com

AsiaA.C.E. (Shanghai) Trading Co. Ltd.6P, New Shanghai International Tower360 South Pudong RoadShanghai 200120 China


Atlas Converting Equipment (India) Pvt. Ltd.Plant No.13, Extension Office BuildingEastern Express HighwayPirojsha Nagar, Vikhroli (East)Mumbai 400 079 India


www.atlasconverting.com/upgrades

Upgrades and Retrofits - Atlas

Data is non binding. Contents are subject to modification without notice. © Atlas Converting Equipments Ltd. 2013

Atlas Controls Rewind Positioning Drives Contact Pneumatic &Model Arms System Rolls Hydraulics

CS 2 TS 350 CW 2 CW 500 CW 900

CW 1000 CW 960 OCS 2 OCSE 620 CSE 1000

Plastic Film

CW (Centre Winders)

CSE (Centre Surface Winders) X X

OCSE (Overhead Centre Surface Winders) X X

TS (Turret Slitter Rewinders) X X

Labelstock & Paper

CS (Centre Surface Winders) X X

OCS (Overhead Centre Surface Winders) X

Universal LS (Centre Winders)

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