Automation solutions for the production of braids

Dennis Behnken, Herzog GmbH

Herzog GmbH is the technology and world market leader for braiding and winding machines. Founded in 1861 and family-run in the fifth generation, Herzog claims to be a pioneer not only in braiding technology itself; but also, to develop and offer modern and contemporary automation solutions for the production of braids in a wide variety of application areas. Specific customer needs are usually the trigger for developments here.

Due to the application-specific but also geographical versatility in the use and production of braids as well as the associated variety of machines, there is no “one” automation requirement. Herzog produces, among other things, machines for textile applications such as shoelaces and trimmings; but also for candle wicks, safety and climbing ropes, fishing lines and net braids, marine and offshore ropes, hoses and filter meshes, sutures and braids for medical applications, packing meshes, wire meshes, cable harnesses, fiber bundle components, etc. in vertical, horizontal, hanging and radial designs ; Numbers of bobbins from 3 to infinity; Braid diameter 0.01mm – 400mm plus; Winding volume from 0.5 – 1,130,000 cc.

With all of this, it should be noted that braiding is a two-step process: the material must be wound onto the spool. The wound bobbin is then placed on a bobbin carrier, which is moved in a defined path, driven by impellers. Both processes are subject to automation.

Automation means setting up and carrying out work and production processes in such a way that people do not need to be directly involved in their operation, but rather all processes, including their control, regulation and partial control, take place automatically. (Duden Economy from A to Z: Basic knowledge for school and study, work and everyday life. 6th edition Mannheim: Bibliographical Institute 2016. Licensed edition Bonn: Federal Agency for Civic Education 2016). This particularly affects the following aspects in the production of braids:

1. The applications for braiding techniques go far beyond the classic “ropes”. There is not always a fixed number of horn gears and carriers or rigid gear tracks. Particularly noteworthy here is the automation of the braiding process for connecting the inner core braid with the cover braid by twisting via a twist switch.

2.Special applications require sensor-controlled insertion of solid objects (e.g. floating bodies, zinc rope, etc.). The take-off speed is adjusted as desired during the process and can be adjusted using a partial length control. This means that the same braiding angle can be guaranteed, even if the diameter changes.

3. The originally textile machine technology of braiding is also used in the processing of wires; e.g. in the production of stents. Here, closed braid ends are braided mechanically using so-called precursors, which only hold opposite wire ends. Furthermore, several wires can be twisted automatically and configurations can be changed.

4. Other braiding processes that were previously manual have also been automated: combination of flat and round braids; diameter changes, insertion of identifying threads, color and/or material changes as well as pattern changes by moving in and out of bobbin carriers.

5. The so-called variation braiders enable even more extensive automation. Various bindings, including changing ones, can be created on these. These include highly flexible braiders for different braid constructions with a changing number of bobbins as well as split braids (alternating weaves).

This not only requires a braiding machine with a complex but easy-to-use control system. But also a software program, “CAB Soft” for the variable design of braids/products including geometric simulation of the bobbin movements. This includes the placement, deletion and color change of carriers, the switching of switches, the activation, deactivation and change of direction of horn geards and an anti-collision test.

6. But there are also different solutions for collecting machine data (MDE) and operating data for conventional braiding machines as part of automation and digitalization. The scope depends on the equipment of the machine, but is generally also possible for machines with a mechanical trigger via change wheels. Logo control is used here. If necessary with display.

For braiding machines with a PLC-controlled take-off, the MDE/BDE is provided via the control itself and an OPC/UA module. However, OPC/UA is also possible for machines with mechanical controls. However, systems for storing data in a database and analyzing the data are deliberately not part of the scope of delivery and must be implemented by a local or external software provider/consultant. This is due to the heterogeneity of markets, customers and applications. However, this allows for individual design options.

The above statements show that extensive automation and digitalization of braiding machines is also being developed and offered to market maturity - at least at the technology leader Herzog. On the one hand, this is achieved through a mechanical and control expansion of the braiding options, accompanied by variable design of braids using simulation by CAB-Soft. On the other hand, various solutions for machine and data acquisition are offered for different machine types.

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