spectrum TEXTILE - Siemens is conquering the Asian market for ... spectrum textile 2003 2 ... servo motor produces the superimposed

October 2003

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spectrumInnovative Solutions for the Textile Industry

TEXTILE

Turn-Key in Mezzogiorno

Simple and Reliable – Sitex knits perfectly

Turn-Key in Mezzogiorno

Simple and Reliable – Sitex knits perfectly

Innovative Machines for Innovative ProductsInnovative Machines for Innovative Products

TRENDSInvesting in a secure future

3 Thinking AheadPartnership with Siemens for a secure future

CASE STUDIESSpinning

5 Universally WoundTotally Integrated Automation in the winderproduction

6 Success in the Far EastNeumag is conquering the Asian market for staple fibre machines

7 Polymers Spun into Fine FibresSiemosyn synchronous motors for manufacturingplastic fibres

8 Turn-Key in MezzogiornoIntegrated automation solution in themanufacture of polyester fibres

10 Record BreakingAksa Acrilic relies on Siemens technology forspinning acrylics

11 Closely SpunMarzoli-Vouk and Siemens cooperate in the area of short staple spinning machines

Fabric15 Duo perfetto

Circular knitting machines with Sitex

17 Simple and ReliableSitex knits perfectly

18 Labels on EndMasterdrives provide perfect labels

18 From Loom to High-tech MachineNew drives for high performance in the carpet factory

20 Succcessful Stitch-bonding with SimotionShort staple spinning machines

Nonwoven21 Efficiently Wound Up

Flexible solution for progressive windingtechnologies with the winding calculator

22 Innovative Machines for InnovativeProductsThe Dilo System Group has relied on Siemenstechnology and support for years

24 Producing Nonwovens under PressureAquaJet production line from Fleissner

spectrum textile 2003

2

Dying and Finishing25 Quality Felt Guaranteed

Textile refinement plant renewed with WinAC MP

27 Gentle Wash CyclePost-treatment of textiles optimized withuniversal automation

28 Smart and InnovativeModulare machine automation in textile finishing

29 High-quality for Strong BrandsProfibus enables the production of high-qualitymaterials

30 Marvelous Printing ResultsRevolutionary textile printing technology twinnedwith state-of-the-art automation

Weaving Preparation26 Future-proof and Flexible

High-performance warping machine SuckerComwarp with MP 270B Touch

SYSTEM SOLUTIONSSpinning

4 Wound up in no Time at AllFilament winders place high demands onautomation

12 Best Spinning Results GuaranteedUniform drawing of slivers with integratedautomation

Fabric16 Success made by Sitex

Technology for tomorrow’s trends

19 Time to Say Good-byeThe weaving machine goes modular withSimotion

20 Optimum Solution with a Great EffectBiaxial machines exploit the flexibility of Simotion

PRODUCTS

31 Productive Platform

Strong in Weak Mains

14 Geared up for All Drive Tasks

One Platform for All

SOLUTION COMPETENCEService & Support

13 A Close NetworkService and support worldwide

14 Total Equipment from A to ZWKC accompanies customers through the wholelife cycle of switch cabinet building

14 Made-to-measure SolutionsChemnitz application center on the road to success

CONTENT


3TRENDS

Today, the innovationcapability of the au-tomation supplier is

more important than ever,as is his ability to responddirectly to his customers’requests. No matter how in-novative they are, products– on their own – are no longer enough.The motto now reads “Identify trends and respond accordingly”, be it with inno-vative systems, intelligent solutions orunique services.

One of the most important trends inthe textiles industry is the apparent movetowards modular machines and systems.The dedicated systems still prevalent to-day are gradually being superseded by amodular system with standard units anddistributed automation concepts. This of-fers considerable benefits, particularly interms of project duration. In addition, theuse of tried and tested modules in hard-ware and software results in improvedquality.

Modular machine manufacture

What is more, modular machine conceptsare increasingly replacing mechanicalcomponents with electronic components(e.g. electronic gears). That means thatsingle drives substitute the vertical shaft.The various mechanical machine compo-nents can be designed, built and modifiedseparately and assembled individually,thus increasing flexibility and reducing

commissioning time. With its distributedautomation structures, in conjunctionwith the Simovert Masterdrives andSinamics drive systems (see also page 31),Siemens is able to offer integrated solu-tions for textile machine building.

However, optimum modularity can on-ly be achieved in conjunction with theSimotion motion control automation sys-tem (see also page 32). The central leadcontroller, e.g. a Simatic controller, con-trols the interaction of the entire system.To save space, the modules are integratedin Simotion D (drive-based) and automat-ed in the Sinamics drive.

Innovative service concepts for more profit

“Mechatronic Support” is an innovativeservice concept that Siemens is alreadyusing with great success. It enables proto-type design – generally a very costlyprocess – to be carried out using virtual

prototypes. This not only saves time but is also considerably less risky: the result-ing prototype instantly meets all require-ments. Time to market, as well as designcosts, are dramatically reduced as a result.Ratio potential can also be achieved by of-fering complete solutions, e.g. a fully as-sembled, tested and customized controlcabinet that can virtually be deliveredwith Plug and Play functionality to the endcustomer’s production line.

Together into new markets

Another discernible trend in the textilesindustry is the move towards the full-scope supplier, whereby the end customerwants everything for his new productionline to come from the one source, withvertical and horizontal integrationthroughout the entire process. To be ableto meet these and future challenges, whileat the same time developing new markets(e.g. Asia, in particular, China), textile ma-chine manufacturers need a strong part-ner at their side. In Siemens they have justsuch a partner, experienced and focusedon the textiles sector. As a “global player”with an extensive, global service network,Siemens can support them with individ-ual solutions, efficient systems and inno-vative service concepts. ■

Partnership with Siemens for a secure future

Thinking AheadManufacturers of textile machines and systems have to bring their innovations to market more and more quickly and cost-effectively, while alsosupplying their machines with precision, speed and flexibility. At the sametime, end users are pushing for a low total cost of ownership, increasedproductivity, secure investment and quality. For all those involved – including the automation supplier – this means: Only those who have thecourage to invest in new technologies will have the best chance of success in the future.

Investing in a secure future

We are acompetent andreliable partner for the textilesindustry. Together,we want to workwith you to

develop the solutions ofthe future”.

Norbert Brenner, Head of Business Develop-ment for Textile MachineAutomation

“


4Spinning

SYSTEM SOLUTION

Spinning speeds of up to 8000 metersper minute are not unusual in mo-dern synthetic fiber plants. They are

a great challenge for the winder that fol-lows after the Spinning process. After all,it has to remove two to twelve filamenttows at this speed an wind them. To keepthe spinning process from being interrup-ted, the full bobbins are changed on thefly.

Not only are the speeds impressive,though, but also the dimensions. Weig-hing up to 35 kilograms, a bobbin can takeup several million meters of thread. Thebobbin build-up determines the draw-offscuttle of the yarn and the possibilities forfurther processing it. Depending on theapplication, synthetic yarns have very dif-ferent technological properties. This alre-ady has to be taken into account in the pa-ckage build-up.

High-capacity winding technology

Today, most filament winders are corewinders – that means that the tensioningspindles are directly driven. A powerfulservo motor produces the superimposedtraversing movement. Individual drivesare used with the winding spindles andthe traversing (yarn placement) to attainmaximum possible flexibility in the inter-action of the units and thus for the packa-ge build-up. A gauging roller measuresthe circumferential speed of the bobbinsand reports it to the diameter calculator.The movement of a rotary table compen-sates for the increasing package diameter.The bobbins are changed on the fly: empty

tubes are accelerated to the spinningspeed, the full bobbins swing away fromthe gauging roller, and the threads are cutand caught by the new tubes.

A good change(-over) with Simotion D

The breakneck speeds in the productionprocess place very high demands on thedrive and automation system. It must bepossible to replace defective winders veryquickly during operation. This requiresautomatic addressing of the new winder.

With its 4-axis control, the drive-basedmotion control system Simotion D fulfillsall the requirements of an automationsolution for demanding winder systems.

Simotion combines motion control as wellas technological and drive functions inone hardware and software solution. Itmasters technological functions such ascalculations for the traversing processesand the diameters of the bobbins just aseasily as motion control functions – suchas positioning the rotary table and run-offcontrol. High flexibility is in demand par-ticularly in the textile industry: in addi-tion to fast change-over times, Simotion is distinguished by the free selection ofreeling modes. To ensure high quality, allbatches can be reproduced at any timeusing an integrated recipe memory. Withits graphic programming, the system alsoproves itself to be extremely user-friendly.

Simotion has another advantage in sto-re for the user: The Scout engineering

system is a tool that contains every-thing that users need to configurethe hardware, parameterize the dri-ves, plan and program the functiona-lity, as well as perform commissio-ning and testing. Extensive diagnos-tic tools and simple dialog guidancemake the system transparent andsimple to use. ■

Filament winders place high demands on automation

Wound up in no Time at AllIn synthetic fiber spinning plants, winders complete the spinning process. Theextremely fine threads are wound from the spinning nozzle onto the oversizedbobbins at a high speed. The bobbins are changed without interrupting thespinning process. In this area of application, the intelligent motion controlsystem Simotion shows its advantages: The combination of motion control,technological functions and logics ensures high flexibility, short change-overtimes and user friendliness.

Servo-traversing Traversing beam ThreadsBobbin drive 1

Switchcabinet

Rotary table

Bobbin drive 2 Servo-rotary table Ejector Bobbin

ChuckTube

Gaugin roller

Principle of a filament winder

pe and fiber material. The winder natural-ly changes bobbins completely automati-cally.

A challenge for drives

From the controller to the operator panel,Barmag has automated the Baby ASW withSiemens components. The winder is con-trolled by a Simatic S7-300 controller.Winding yarns with a particular tensileforce is especially challenging for the dri-ves: at the beginning of the package build-up, the drive starts running at a highspeed, and as the bobbin diameter increa-ses, the speed is reduced correspondingly.The 4 drive axes of the machine are con-trolled by Masterdrives VC Kompakt Plusand MC Kompact Plus. With their highinitial frequency, they are almost ideallysuited for this application area. The highresolution of the speed and actual-valuemeasurement ensures that the speed set-point is exactly maintained.

The high-performance hardware per-fectly implements the software specifica-tions. For an exact and trouble-free win-ding, the program must carry out conti-nuous diameter calculations and computethe depositing angle of the yarn for thetraversing disturbance method. For thedrives, this means implementing accuracyin the speed ratio up to the third decimalplace.

Open for expansions

All components are integrated in TotallyIntegrated Automation (TIA). End custo-mers appreciate TIA’s high degree of inte-gration since winders are always part of aspinning plant. In this way, the machinescan also be easily coupled with third-partyproducts. In addition, TIA offers an open-ness in technology that is equally useful tothe OEM and end customers. This allowsBarmag to integrate their own enginee-ring know-how at any time. The plantoperator has the possibility of optimizingthe bobbin build-up and thereby obtai-ning market advantages as a result. How-ever, choosing standard products fromSiemens was a good decision for Barmagin another respect as well: their remoteservice capability makes it possible to sol-ve problems quickly via remote diagnos-tics. Furthermore, Siemens is representedby service points worldwide. As a result,customers from all over the world have noproblem with the service. ■


5CASE STUDY

A round 140 years of experience intextile machine manufacturingpredestine Barmag Spinnzwirn

GmbH for winder manufacturing. In addi-tion, this medium-sized company fromChemnitz, Germany produces slit filmyarn production lines as well as twistingand air texturing machines. The high ex-port share of 80 percent to all five conti-nents also demonstrates the quality andlevel of recognition of the company.

Barmag carries the compact automaticwinder Baby ASW in its range specificallyfor winding technical yarns. The well-en-gineered mechanics with reliable, inver-ted-thread traversing has proven itselfvery well in this machine.

The spun yarn is wound onto cardbo-ard tubes at speeds of up to 4500 metersper minute – depending on the winder ty-

Total Integrated Automation scores points in winder production

Universally WoundThe most important characteristics for filament winders are an optimumpackage build-up and flexibility. Barmag Spinnzwirn is a company rich intradition that develops and produces high-performance winders for syntheticfilaments. Since all winders are part of a spinning plant, integrated automationapproaches has proven very successful. This was a reason for the company touse control and drive technology from Siemens.

Spinning

Barm

ag

Filament winder Baby ASW

N eumag has been producing ma-chines and plants for the syntheticfiber industry for more than 50

years. The synthetic fibers are cut in thestaple fiber process into fiber “staples” af-ter spinning and stretching, i.e. fiber sec-tions of an exactly defined length. Thesecan then be processed further – for exam-ple for the clothing industry. The provenNeumag production process is a synonymfor best fiber quality and maximum pro-duction efficiency.

Large-scale plants secure market advantages

The trend in staple fiber machines is mov-ing towards large-scale plants with a ca-pacity of 200 tons a day – a trend that Neu-mag has influenced decisively. 200-tons-a-day lines are an important contribution toreducing production costs and are there-fore what customers prefer.

A big order in Asia for the productionof “cotton-type” polyester-HTHM-staplefibers will further expand the world lead-ership of the company in this field. Elevenof these jumbo plants are presently inproduction, assembly or commissioningto produce polyester fibers on the Asianmarket.

All inter-adapted

This success is no coincidence. Neumagemploys the finest in automation anddrive solutions for implementing theirprocess know-how in their plants. Thepowerful, easy to operate controllerSimatic S7-400 is used as a PLC in the sta-ple fiber plants. The modular SimovertMasterdrives VC enable an ideal and low-

With Siemens as a partner Neumag is conquering the Asian market for staple fiber lines

Success in the Far East

Neumag, a member of the world’s largest textile machine manufacturer Saurer, and worldmarket leader in the fields of staple fiber lines and BCF machines (Bulked-Continuous-Filament) is well positioned in the Asian market. The company is currently handling theworld’s largest polyester staple fiber project. Neumag is supplying not only the spinning milland fiber line equipment but also the entire engineering and process know-how. Theuniform automation with Siemens components guarantees the customer an integratedsolution from a single provider.

The Neumag Jumbo staple fiber machinesspin, stretch and cut the fibers

Neu

mag


6Spinning

CASE STUDY

cost solution over the whole performancerange of the spinning and fiber line – evenwith different motors such as the perma-nent magnet-excited synchronous motorsSiemosyn 1FU8 and the standard asyn-chronous motors 1LA / 1PQ. The robustSimatic Rack PC 840 puts a high-end de-vice at the customer’s disposal which of-fers a wide range of extension and expan-sion possibilities as well as integrated

monitoring functions. A comfortable HMIconcept for the plant is also important tothe user of course. And the process visual-ization system Simatic WinCC provideshim with the ideal software.

This single-source solution offers theend user a number of advantages: Apartfrom having a single contact for all ques-tions and application tasks, he gets com-patible interfaces and is able to save stockcapacity. The customer also benefits fromthe three-fold uniformity of Totally Inte-grated Automation in terms of communi-cation, configuration and data storage. ■


7CASE STUDY

When synthetic fibers are processed,one process variant is spinning thepolymers into filaments in continuousfiber spinning mills. The high stan-dard of quality and the simultaneouscost pressure in the textile fieldrequire a fully developed automationtechnology: the Zimmer AG of Frank-furt ensures its competitive edge byusing the Siemosyn motor 1FU8 forthe spinning pump drives.

A s a technology leader, the ZimmerAG owns and employs a multitudeof sophisticated processes, cover-

ing the entire lifecycle of polymers, syn-thetic fibers and thermoplasts from pro-duction to recycling. Just to mention a fewapplications, Zimmer is building plantsand machines for the production of textilefilaments, staple fibers, tire cord, carpetyarns and products for further processinginto packaging foils, PET-bottles and tech-nical films

Melted, pressed and cut

Zimmer uses the melt spinning method toproduce polyester and polyamides. A PETpolycondensation line continuously sup-plies liquid polymer to the direct spinningline. The melted mass is distributed to theindividual spinning points by the spin-ning bar and is pressed through the spin-ning nozzles by the spinning pumps withan even conveyance speed by the spinningpump drives. This produces fine filamentsthat are cooled with conditioned air, oiledand collected to form filament bundles.After the bundles have been placed inspinning cans over discharge units and byreel plaiters, they are ready for furtherprocessing.

For further processing in the textilearea, the filament is cut into staples. Thestaple fiber production lines of Zimmerthat are connected to the direct spinning

mill offer a complete package of technologyfor this. One plant in India with a capacityof 120 tons per day and two plants in Chinawith a capacity of 150 tons per day eachhave been successfully commissioned.

Efficient automation – economical production

State-of-the-art textiles with consistentquality and low prices – that means thatproduction line constructors have to con-tinuously design manufacturing processesthat are more and more efficient. The man-ufacture of high-quality fibers, in particu-lar, demands high-capacity and fast au-tomation technologies with precise, speed-variable drives.

The Siemosyn IFU8 permanent-fieldsynchronous motor has optimally provenitself for the drive system of the spinningpump. It is especially suitable for singledrives in which load-independent, synchro-nous and frequency-proportional speedsare required, and for group drive systemswhere several motors are controlled syn-chronously by one frequency converter.The motor convinced Zimmer with its es-pecially economical operation: it has amagnetically active rotor and requires sig-nificantly less reactive power than otherdrives. The bearing lifetime and oilserviceintervals for Siemosyn 1FU8 are at least40,000 hours. As a result, the company wasable to extend the maintenance intervalsfor the spinning pump drives considerably.

Another Siemosyn motor is used in thereel plaiter drive of the discharge unit. As a frequency converter for the distributeddrives, Zimmer decided on MicromasterMM 440 with Profibus connection to theSimatic S7-400 controller. This ensurescontinuity on all levels.

The tried-and-tested 1LA asynchronousmotors provide reliable service in all maindrives of the staple fiber production line.Simatic S7-400 and Masterdrives for drivecontrol, servo-control and setpoint cascad-ing provide continuity here as well. ■

Siemosyn synchronous servomotor for manufacturing plastic fibers

Polymers Spun into Fine Fibers

Spinning

After being pressed through thespinning nozzles and being cooledwith conditioned air and severalother processing steps, the fila-ments are placed in spinning cans

Zim

mer

AG

technical installations, acceptance testsand deliveries so that the building site op-erations went by without any hitches. In-stallation began after the complete deliv-ery of all components in June 2002. Thespinning mill was commissioned opera-tion first in November, followed by thefiber line.

Efficient and failsafe automation

For automation of the plants, Montefibrerequired a central operation and controlsystem. Simatic S7-400H and WinCC arethe ideal duo for this. Redundant operat-


The Montefibre company becamewell-known in 1957 with their brandname Terital. The products are used

in all areas of application of textiles: tech-nical, medical and household textile ap-plications. A plant for manufacturing thefibers is located in Acerra. However, theproduction capacity in the Southern Ital-ian town was no longer sufficient, prompt-ing Montefibre to launch an expansionproject at the beginning of 2001. In thenew spinning mill, the polymer is spuninto fibers in 30 positions and stored incans. A logistics system supplies the cans

at the right time and in the desired qualityto the staple fiber plant. Up to 150 tons offibers per day can then be furtherprocessed and pressed into bales.

In May 2001 Siemens received an orderfor providing the plant’s electrical equip-ment. The technical details then had to be discussed with Montefibre and Ems Inventa Fischer. Siemens also took overthe scheduling of deadlines and was thegeneral point of contact for everythingconcerned with their own scope of deliv-ery. The experienced electrical supplierplanned deadline agreements, electro-

Integrated automation solution in the manufacture of polyester fibers

Turn-Key in MezzogiornoOne of the leading manufacturers of acrylic and polyester fibers in Europe –Montefibre SpA – has expanded its production in Acerra near Naples for acapacity of 50,000 tons per year. The newly installed polymerization, spinningmill, stores logistics and staple fiber plant all meet the latest requirements.Montefibre got a license for the process technology from Ems Inventa Fischer.An Italian company did the assembly and installation. Siemens was responsiblefor the electrical engineering in the spinning mill and the fiber line as well asfor the overall coordination.

8 CASE STUDYSpinning

Machine controls, drives, auxiliaries, ET 200

Plant Ethernet networkTCP/IP

PLC:SIMATICS7-400H

PROFIBUS

1

Industrial Ethernet

Spinning line Fibre line

2

1

2

1

2

Redun-dancy ofserver 2

Redun-dancy ofserver 1

PLC:SIMATICS7-400

PROFIBUS

IndustrialEthernet

Client station WinCC

Mainop-stationsWinCC/Server

Machine controls, drives, auxiliaries, ET 200

Automation concept of spinning and fibre plant

sioning of the electrical equipment. Tech-nical clarification and engineering coordi-nation with the customer and subsequentacceptance took place according to sched-ule. Coordination with Montefibre, Snam-progetti and Inventa Fischer worked per-fectly. A firm basis for providing the hard-ware and software engineering was creat-ed for Siemens by joint technical discus-sions, clarification of requirements anddefinition of interfaces to other produc-tion processes.

Planning commissioning was not easyon account of the problems on site. Agreat challenge for the project manage-ment was the flexibility in personneldeployment and the close cooperation of the partners. Montefibre is therefore very

pleased in retrospect, and, confirms thatSiemens supplied the electrical equip-ment like the customer requires it and of-fers service and support for cost-effectiveoperation.“ ■

ing stations guarantee uninterrupted op-eration if a station should fail. The redun-dant Profibus communication with theSimatic S7 controller and the WinCC oper-ating level ensures high availability. In ad-dition it supplies information for efficientmanagement.

The main drives in the spinning millsuch as spinning pumps and take-off as-semblies consist of Siemosyn permanent-field motors with Masterdrives converters.Their highly accurate, digital speed con-trol provides optimum operating results.All drives are linked by an intermediatecircuit and backed up by Masterguard asan independent power supply so that abrief power failure or interruption doesnot necessarily close down operation.

Distributed systems and operating safety

Simatic S7-400 with redundant WinCC op-erating stations is also used in the fiberplant. All drives and the process controlare controlled via Profibus. DistributedET200 S reduce the amount of wiring inthe plant and also supply all the informa-tion for control and visualization to theSimatic via Profibus. The WinCC stationsenable direct management, supervisionand logging of production. The operatorhas the advantage of being able to outputerror messages, reports, diagrams orcurves on printers.

The speed-controlled drives allow ahighly accurate setpoint control. Master-drives converters supply the asynchro-nous motors up to 700 kW of power. Elec-

tric brakes mounted directly on the mo-tors ensure safe stopping. Modern MCCslide-in drawer technology of the Sivacontype controls and monitors the auxiliarydrives. Trigger signals and messages aretransmitted via Profibus to the Simaticwhere they are processed. The highlycompact modular design allows a space-saving layout without impairing flexibilityin the scope of functions. Accessory mod-ules such as soft starter, right-left handrotation and temperature monitoringmodules extend the performance.

Information integration ensures high quality

Market requirements also demand consis-tent quality documentation throughoutall production stages from Mon-tefibre. A central control com-puter therefore saves all the datafor production control and qual-ity monitoring. All productionunits are connected via Ethernet,each unit acquiring data accord-ing to a method developed byMontefibre and passing it on tothe control computer.

The spinning mill receives thedata for the next batch and re-ports back information on com-pleted production runs. Thisprovides quality-relevant infor-mation which can be put togeth-er in a quality report at the endof production as required.

The fiber line receives all thedata from the production logis-tics and also passes on data tothe bale presses. For example,the energy requirements or the produc-tion process can be analyzed or archivedas a log. The WinCC system provides thedata and allows preconfigured evalua-tions or custom trend curves of importantprocess variables. The integrated linkingof the devices under the TIA concept withProfibus serves as a basis. This allows lat-er expansions and adaptations withoutany problems. The TIA concept also sup-ports the tight integration of the automa-tion levels and allows access to all infor-mation of the PLC, WinCC and the drivesvia the Profibus.

Siemens a competent partner

Siemens was responsible for coordinatingand handling the delivery and commis-


Gei

ßelb

rech

t

The new plant went into operation in May 2003and increases production capacity in Acerra by50,000 tons per year

Mon

tefi

bre

9


10Spinning

CASE STUDY

The use of Simovert Masterdrives VCin two spinning lines of a Turkishsynthetic fiber manufacturerguarantees high user-friendliness andprecise diagnostic capability inaddition to high accuracy, stabilityand maximum speed.

The Aksa Akrilic A.S. company found-ed in 1968 in Istanbul with its plantin Yalova specializes in the manufac-

ture of acrylic fibers. With an initial pro-duction of 5,000 tons, Aksa now produces250,000 tons a year, 8.5 percent of thetotal world production, and is one of the most important economic forces inTurkey.

The raw material of the acrylic fibers is a synthetic polymer which is pressedthrough the narrow holes in a spinningplate. Aksa uses the wet spinning tech-nique in which the polymer solution ispumped through the spinning nozzles di-rectly into the coagulation bath where theindividual threads solidify.

Convincing Siemens technology

The fast-growing company decided tomodernize build two new spinning linesmechanically and electronically. Drive sys-

tem modernization were made withSiemens technology. In addition to thetechnical implementation Siemens alsosupplied the concept: two 710 KilowattSiemens AFE (Active Front End) feed-re-turn units feed 34 Masterdrives VC with a common DC bus. The drive consists ofmotors of the 1LA type and the controlleris a Simatic S7-400. The second AFE servesas a standby unit in case the active unitshould fail whereby the speed of the mo-tor remains unchanged.

“One of the main reasons why we chosethe AFE is the suppression of the harmon-ics at simultaneous high immunity to volt-age interruptions,” Mustafa Yilmaz, Man-aging Director of Aksa A.S. explains.

Simple modifications

The very specific demands of the textilefirm on the system control were met onthe basis of Totally Integrated Automation(TIA). S7-400 communicates with thedrive via Profibus DP 12 Megaband. Thedisplay is provided by the new S7 softwareand the HMI system Simatic WinCC. Avariable-speed setpoint cascade manage-ment was particularly important to thecompany because it means that the main-tenance staff can modify the setpoint cas-cades and switch the drive on and offwithout having to change the control soft-ware.

Former solutions more complicated

The system used to have to be shut downduring the changeover to the standby unitin the event of a fault. In addition, the rec-tifiers generated harmonics, and modifi-cations of the HMI entailed complex pro-gramming.

In a later variation the communicationbetween the implemented control anddrive technology was omitted: the set-points were transmitted to the drive viaanalog outputs which meant that the reso-lution and stability were unsatisfactory.

Beneficial development

The project had to be completed withinjust 15 weeks – including the engineering.The short delivery times, high technicalstandard and expertise of the Siemenspersonnel made it possible to reduce theproduction time to eight and the commis-sioning to seven weeks. The Managing Di-rector Mustafa Yilmaz lists the advantagesof the Siemens system: The user-friendlystructure of the setpoint cascades, thedigital communication of the drive withthe control and the HMI thanks to TIA, thehigh safety standards and the effectivediagnostic possibilities with WinCC. Hewrote a letter to Siemens where he ex-pressed his gratitude and promised fur-ther cooperation in the future. ■

Aksa Acrilic relies on Siemens technology for spinning acrylics

Record Breaking


11Spinning

CASE STUDY

Marzoli-Vouk and Siemens cooperate in the area of short staple spinning machines

Closely SpunThe Italian company Marzoli has been shaped by over 100 years of experi-ence in the area of short staple spinning. In order to ensure a continuousdevelopment of their machine range, the firm has joined together withSiemens to automate their machines. The coordinated automation compo-nents cover virtually all requirements of Marzoli’s spinning machines.

can be installed right where they areneeded on the machine. The integratedProfibus ensures a trouble-free datatransmission with only one communica-tion cable. All interferences that can occurwith direct cabling between the CPU anddrives or distributed I/O’s are thereforeprevented from the beginning. The literal-ly “driving force” in Marzoli’s machines is an extensive and reliable family of mo-tors, starting with the asynchronous mo-tors 1LA7 and extending to 1FK7 and 1FT6servo motors. These motors are alreadypre-configured in the Simodrive 611U andMasterdrives drive families, which guar-antees a fast system start-up.

The multi-motor drive concept allowsan optimum arrangement of the drives.The elimination of mechanics and the newdimensioning of the drives make it possi-

M arzoli S.p.A. is one of the world’sleading manufacturers of spin-ning machines in the short

staple area. Marzoli produces complete,turnkey plants together with the VoukCompany they had acquired in 1999. Thedelivery program of the company includesmachines for processing cottons, synthet-ic fibers and blends of these – from balesto yarn.

More innovative with modules

In order to maintain their position on themarket, Marzoli is equipping their ma-chines such as the card, flyer, draw frameand combing machine with the latest au-tomation technology. In this case, thecomprehensive Siemens solution offersthe advantage of an integrated and com-pletely compatible automation architec-ture.

Innovations in hardware and softwarecan quickly flow into the latest generationof machines owing to the modularity ofthe implemented components and thetransparent programming. With theSimatic S7 controller, inputs and outputs

ble to achieve considerable energy sav-ings with the flyer while increasing pro-ductivity at the same time. Batch changeand machine settings now only require afraction of the previously required time.The user can set all speeds convenientlyon the display.

Universally advantageous

The backbone of this integrated automa-tion architecture is the Totally IntegratedAutomation (TIA) concept. Many innova-tions only became possible with TIA. Justone example: As a result of the bus con-nection, flyer sensors and cables for de-tecting the spindle rail could be elimi-nated. Prototypes can already be supple-mented and adapted to changes duringmachine development.

One for all

Siemens as the one-stop supplier for theentire machine and plant automation –this solution was deliberately chosen byMarzoli-Vouk. Today, the company greatlyappreciates the advantage of working witha single partner who is responsible forquality, mutual integration, applicationsupport, and assistance after sale aroundthe globe.

A constant dialogue between Marzoliand Siemens ensures that Marzoli’s ma-chine range is continuously improved andinnovated. The results of this cooperationare presented at this year’s ITMA, provinghow using innovative automation technol-ogy can enhance technology expertise inmachine building. ■

Mar

zoli

Mar

zoli

Mar

zoli


12Spinning

SYSTEM SOLUTION

S ix to eight slivers from the card arefed to the draw frame through an in-feed gate. There they pass a meas-

uring device which measures the sliverthickness. The measured values arebuffered, evaluated and sent to the draw-ing machine as a speed setpoint at theright moment. There the slivers are drawninto a single sliver of constant thickness.The faster this regulating process is per-formed, the better the sliver quality. At de-livery speeds of 1,000 meters per minute,great demands are placed on the automa-tion solution.

Efficient drive concept

Up till now, all drive tasks have been ac-complished by a central asynchronous

One step ahead with Simotion and Sinamics

The task of the automation is to guaranteeexact speed synchronicity of the fourdrives – especially at machine start andstop and in the event of a power failure.The Motion Control system Simotion Dand the Sinamics S drive system offer afully integrated automation solution fromone provider which is tailor-made to ide-ally meet these requirements. Logic pro-cessing, movement and drives are inte-grated on one platform; the user onlyneeds one simple engineering tool forcontrol and drive. Simotion also offers the advantage of multi-axial drive control.The double axis modules used on the reg-ulated draw frame save costs. The provenDC-bus means that kinetic buffering is nota problem either. Mechanics can also bereduced.

The space required for the switch cabi-net is a decisive factor for all textile ma-chines. The small dimensions of Sinamicsare therefore an advantage. With the DriveCliq interface, Simotion/Sinamics offerseven greater benefits: The highly efficientinterface is responsible for data exchangebetween the Sinamics modules and can al-so be used for remote diagnostics. That isimportant because the spinning mills areto be found above all in India, Asia or Chi-na. In these countries, safety in the eventof power fluctuations and a good short-circuit-ground short-overload protectionis very important. These requirementshave naturally been considered in the de-velopment of the Sinamics series. ■

Uniform drawing of slivers with integrated automation

Best Spinning ResultsGuaranteedStaple fibers first have to pass through a complex process on the way to high quality yarn. The draw frame plays an important role in quality production here because all failures in the drawingframe sliver turn up again in the yarn. In order to meet the related high automation requirements,Siemens offers a high quality solution. A mature automation concept with Simotion and Sinamics has many benefits for the machine.

motor. Gears and the appropriate changegear wheel which allowed individual adap-tion to the technological requirementswere used to set the different speeds. Onregulating draw frames there was also aregulating drive which regulated the sliv-er thickness to the desired setpoint. Themodern automation solution consists offour single drives which interact accord-ing to the required functions. The resolu-tion of the rigid drive assembly opens uppossibilities as yet unknown. For exampledelay values can be set which were notpreviously possible because the teeth onthe change gear wheels only allowed inte-ger values. All speed settings can be madequickly without using tools, even from theforeman’s office if necessary.

Prior to spinning, the fibres are parallelized in the draw frame

2 3 4

13SOLUTION COMPETENCE

A&D customer support is based onfour pillars: These are online sup-port, technical support, service on

site (field service) and the worldwidespare parts and repair service. They en-sure that the customer receives the neces-sary support as required.

Customers of the Motion Control divi-sion of Siemens A&D can consult approx-imately 200 technicians in the technicalsupport centers, eight of which are locat-ed in Germany, four in America and one in China. At these centers, the experi-enced technicians process around 3000inquiries a month reaching then via tele-phone, e-mail or fax, for example concern-ing the functions and handling of prod-ucts and systems, interfaces of system so-lutions, or the layout of drive systems.

Service on site

Over 600 service employees in over 60service points worldwide support cus-tomers just as requested in commission-ing and maintenance. They also work onsite to correct faults.

The job assignments are coordinatedby specialist control centers that can bereached around the clock. An additionalSiemens service is the Repair ServiceContract (RSC). With the RSC Siemens willfix machine failures on site. OEM and en-

duser do not have to pay extra fees in caseservicing becomes necessary.

Spare parts and repair service

Machine downtimes due to mal function-ing equipment or components certainlycannot always be prevented. However,when something happens, a quick re-placement must be ensured, in order tokeep the duration and cost of the failureas low as possible. A sophisticated logis-tics system ensures that spare parts canbe delivered quickly, even if they are notavailable on site. In an emergency, orderscan also be placed outside of the usualworking hours in almost all countries.

While spare parts can usually beshipped within 24 hours in Western Eu-rope, there are time-consuming and cost-ly hurdles for imports in many countries.Lengthy customs procedures, for exam-ple, can delay the delivery of an urgentlyneeded component. For this reason,Siemens A&D maintains regional spareparts warehouses with locally neededcomponents in numerous countries – in-cluding manufacturing countries that areparticularly important for the textile andclothing industry, such as China, Indiaand Pakistan. In this way, spare partsdeliveries are ensured at short notice ifneeded.

Instead of replacing a mal functioningdevice, in some cases it may be quicker torepair it. For this purpose, Siemens A&Dmaintains a worldwide network of repaircenters. Standard repairs are usually car-ried out within ten working days, quick re-pairs within two working days. To repairlarger equipment and installations, thereis a mobile repair service that performsrepairs on site and is also active world-wide.

First aid on the Web

In addition to “hands-on” services,Siemens A&D also provides comprehen-sive, fast information around the clock,365 days a year with their online supporton the Internet. At one address for allproducts and systems, the range of servic-es includes product and system descrip-tions, and the possibility of directly down-loading manuals and software updates. In the case of smaller problems, the usercan directly search the FAQ’s, where themost important and frequent customerinquiries from Technical Support are pre-sented in an easily understandable, prod-uct-specific way and accompanied by ad-vice from specialists. Since good supportalways begins with a name, customers willfind all the regional and worldwide con-tacts that are responsible for their con-cerns in the online support. ■

Service and support worldwide

A Close NetworkHardly any market is more global than the textile market. Textile machinemanufacturers and end customers in the textile industry therefore needglobally active partners who are able to offer comprehensive service andsupport at decisive moments and, when necessary, on site.

Service & Support

Field Service

Fast on-sitesupport all overthe world

Spares and Repairs

Reliable and fast

Online Support

Comprehensivesupport on theInternet 24–71

Technical Support

Direct supportfrom a Siemensexpert on thephone

Detailed information on the services of A&D customer support can be found on the Internet at www.siemens.de/automation/service&support

14Service & Support

SOLUTION COMPETENCE

The WKC company founded in 1992 isone of the youngest and most mod-ern locations of the Siemens group.

Today about 420 employees produce morethan 9,000 electrical cabinets every yearunder the motto “We offer every machinemanufacturer complete solutions withinthe productivity chain”.The secret of theChemnitz company’s success lies in theirwide range of products and services withwhich they meet various customers’needs.

One-stop service

However, the customer benefits, evenmore than from the wide range, from hav-

ing just one partner or the whole cabinetconstruction life cycle. After customerspe-cific consulting, the configuration beginswith the necessary Sinumerik, Simatic,Simotion or Simodrive and Masterdrivesproducts. Customized auxiliary electronicmodules can also be developed and pro-duced on the same site if necessary. Thesophisticated material logistics and pro-curement concepts specially adapted tomeet his requirements and a suitable sup-ply chain management save costs or thecustomer.

Every order is accompanied and exe-cuted throughout by special customerteams. Preferential suppliers provide con-

siderable price and logistics advantages.The machine manufacturer can choose dif-ferent service packs or electrical testingwhich optimize process costs. This meanshe gets pre-tested complete equipment ondemand. The supply logistics is also adapt-ed to customers’ needs. One example areship-to-line concepts or various cus-tomers. WKC fitters provide support or in-stallation and commissioning on request.

The high quality of a electrical cabinetstands and falls with the production team.The customer gets a competent contactpartner for all relevant matters. Checklistsin the production and test process guaran-tee the customer-specific requirements. ■

WKC accompanies customers through the whole life cycle of switch cabinet building

Total Equipment from A to ZThe Chemnitz Werk für Kombinationstechnik (WKC) offers itscustomers custom-made solutions all to do with automation engi-neering. The electrical cabinet builder offers one-stop service –from consulting through hardware and software configurationright up to commissioning.

Chemnitz application center on the road to success

Made-to-measure SolutionsCreative employees are the basis for every success. Siemens has therefore set up their applicationcenter for textile applications in Chemnitz, the cradle of German textile machine construction.Numerous projects have already been completed worldwide to the satisfaction of customers.

The innovative power and the textileknow-how in the Chemnitz regionare still renowned. Many well-known

companies have their roots here. It is anearly perfect location for an applicationcenter that develops customer-specifictextile technology solutions. Every em-ployee of the center is specialized in a par-ticular area of textile machine construc-tion. Examples of expertise include appli-

cations from spinning through knittingand weaving up to finishing machines.

Function objects as a basis

An important task of the engineers in theapplication center is to develop the basisfor textile function objects. In the future,these textile-oriented objects will be madeavailable in the form of a function libraryor serve as the basis for a customer-specif-

ic solution. Together they form a textilefunction pool that can be used for specificproject planning. ■

A view into the Chemnitz switch cabinet production

The director of the application center, Jörg Kroschinski, will be happy to provide you with more information. Tel.: +49 (371) 475-3629, [email protected]


15CASE STUDY

Orizio S.p.A., one of the world’s mostrenowned manufacturers of circularknitting machines is always on thelookout for new solutions to meettheir customers’ requirements. With the piezo-ceramic single needleselection system Sitex, the Italiancompany has found a system thatenables production of new kinds ofmaterials and patterns.

900 employees produce a wide rangeof large and medium-sized Jacquardcircular knitting machines for

Orizio. The machines from Brescia sell ex-cellently not only in Europe but also onthe Asian and South American markets.One of the main reasons for this tremen-

dous success is Orizio’s high innovationpower.

Tried-and-tested electronics for circular knitting

The Sitex automation solution whichSiemens developed specially for circularknitting machines is just the right thingfor Orizio. The company cooperated close-ly with Siemens in the phase of develop-ment of Sitex – and was therefore able toinclude the demands and needs of cus-tomers in the solution. The circular knit-ting specialist particularly appreciatesthat the control system can be adaptedquickly and flexibly to the individual ma-chine types. In addition, pattern files ofvirtually any size and in numerous for-mats can be processed, naturally includ-ing the ORIDES format from Orizio. Thefirst prototype has been in trouble-free

production in three shifts since the begin-ning of 1998 which is proof of the relia-bility of the system solution. The Head ofElectrical Design at Orizio, Filippo Oneda,confirms this: “The electronic single nee-dle selection Sitex runs without problemsand has proven itself in the field. Siemenshas turned out to be absolutely the rightchoice for us.”

Many new possibilities

Sitex can be used in many different typesof machines. The latest example is theCMOE, a double-head knitting machinewith electronic cylinder needle selectionwhich produces double Jersey structuresin Jacquard, Rib and Interlock. Since it hasrecently become available in greater di-ameters up to 48 inches (=121,92 cm), itwill be possible to manufacture new, inno-vative materials from the home textilesand automobile industries on it in future.Mattress covers can now be knitted in onepiece for example. It also opens up totallynew opportunities in the field of distanceknitting with up to ten millimeters dis-tance between the two sides of the goodsconnected by standing threads. They havesucceeded in platting the standingthreads on the inside of the clothes withtotally new lock designs. This avoids un-pleasant irritation of the skin from under-wear.

A proven partnership

The results prove that the close and trust-worthy cooperation between Orizio andSiemens has paid off. In the end, the knit-ters benefit from the pooling of key com-petencies because practical experience isincluded in the electronic development.Orizio uses the Sitex system in two ways.On the one hand the machine manufac-turer is working permanently on the op-timization of existing machines. On theother hand they are developing totallynew models, for example in the area oftransfer or body. The knitter can thenadapt the range of producible materialtypes and patterns ideally to market de-mands. ■

Circular knitting machines with Sitex have proven effective

Duo perfetto

Fabric

Ori

zio

16Fabric

SYSTEM SOLUTION

F ashion trends change almost asquickly as the weather in April – newpatterns are in constant demand, a

rapid and flexible change in patterns is, therefore, required. This is preciselywhere the advantages of Jacquard circularknitting with an electronic needle selec-tion system compared to conventionalmechanical Jacquard heads are. Thepiezoceramic needle selection system isoutstanding due to its especially high se-lection speed, which enhances the pro-ductivity of the individual machines.

With Sitex, Siemens offers the idealsolution for electronic individual needleselection – a solution that has alreadyproven itself in harsh production. Thetotal package includes the piezoceramicneedle selection system Sitex M, the con-trol Sitex CK to prepare the pattern andselect needles, the uninterruptible powersupply Sitex S and the drive system with

Micromaster frequency converter andasynchronous motor for the knittingcylinder.

In this total solution, all of the compo-nents are optimally accommodated to oneanother. Aside from savings in logistics,service personnel training and spare partsmanagement, the advantage of the con-cept for textile machine manufacturers isthat they only have one contact person forthe entire system.

More efficient networking

The internet connectivity is regarded as a special highlight of Sitex. Machines can be networked with little expenditure forhardware. They are just a mouse clickaway from partner businesses, design stu-dios, the machine manufacturer or othermachines in the knitting mill. It is possi-ble to transmit pattern files from any com-puter directly to the desired target ma-

chine. Even if the control software needsan update, this can be handled online in amatter of minutes. Effective productionplanning and control are the essence ofany knitting mill operation. With internetconnectivity, this is no problem becauseall data are acquired and filed online. ■

Technology for tomorrow’s trends

Success Made by SitexThe optimal, total solution for the electronic equipment of large circular knit-ting machines is called Sitex. The machines, with their piezoceramic individualneedle selection unit, are faster and more flexible. The connection via internetdramatically increases the efficiency of the machines: a systematic solution“Made in Germany”, “Made by Siemens”.

Control Sitex CK for preparation of pattern and selection of needles

Piezoceramic needle selection systems Sitex M

Cylinderdrive

Micro-master

3,5“

Rotating needle cylinder

Webholder

PC

Patternpreparation

SITEX CK

USV SITEX S

Patternoutput

Encoder

Bending transducer modules for SITEX M

Siem

ens

Siem

ens

pability of controllers. “Today, our con-trollers are already network-capable. To-gether with Terrot, we will be showingwhat you can do now with them at theITMA 2003 in Birmingham,” says Dr. Niko-laus Herdegen, the responsible Sitexproduct manager in the Automation ofTextile Machines division at Siemens. Pro-duction machines in a network – this willbe the future for knitting companies aswell. ■


17CASE STUDY

F einjersey, located in the Austrian cityof Götzis, not far from Bregenz, wasestablished around 20 years ago. The

company now has 50 employees and pro-duces jersey materials in the upper quali-ty segment. Only through a combinationof innovative design, high quality andflexibility towards customer wishes cantextiles still be successfully produced inCentral Europe. One of Feinjersey’s owndevelopments ensures that they can offertheir customers 500 new products a year,many of them directly made to measure.The team uses innovative yarns, the latestknitting technologies and creative finish-ing methods to make sure that theircustomers are satisfied. These customersinclude such well-known names as Tri-umph, Schiesser, Calida, Bruno Bananiand Arcte. The current trends mean usingmore and more high-tech yarns, knittingeven more finely, and continuously rais-ing the level of difficulty. This is the onlyway for Europeans to keep far enoughahead of the competition from low-wagecountries. In order to do this, a companyhas to keep their processes under controland use state-of-the-art production equip-ment.

Terrific knitting requires solidtechnology

The main requirements that the Austrianknitters have for their machines are “fastset-up and changeover, simple operation,and consistent quality over a long time”,according to Mathias Schnetzer, the per-son responsible for gray cloth at Feinjer-sey. This is very obviously provided by the knitting machines from the Stuttgartmanufacturer Terrot: around two thirds ofthe 60 knitting machines in Götzis weresupplied by Terrot. Schnetzer: “The Terrotknitted fabrics are more even, smootherand shinier than those from other ma-chines. Our customers also notice this.”

In order to construct such machines, “aclose cooperation is required between the

machine manufacturer and the user,” saysTerrot marketing director Klaus Kunde. Inthe case of Feinjersey, this cooperation iswell established since the 1980’s. Equallyimportant is the cooperation with the au-tomation suppliers.

Increasingly Sitex

On the controller side, Terrot increasinglyrelies on the Siemens solution Sitex CKand Sitex M: a special controller forjacquard circular knitting machines and a piezoceramic bending actuator system for electronic individual needle selection.This system can also score points with theenduser: “On the one hand, Sitex CK isvery reliable and controlled. On the otherhand, the controller is very easy to oper-ate. Even knitters without lengthy trainingcan work with it,” says Mathias Schnetzer.

The latest trends, which Feinjersey alsofollows closely, concern the network ca-

Sitex knits perfectly

Simple and ReliableThe Feinjersey company in Götzis knits very high-quality jerseys for equally demanding customers inCentral Europe. In order to cleanly produce the approximately 500 new cloth products per year,Feinjersey increasingly relies on knitting machines from Terrot with Siemens Sitex CK controllers.

Fabric

K. O

berm

ann

Partners for increasingly perfect mate-rials: Mathias Schnetzer from Feinjersey,Klaus Kunde from Terrot and Dr. NikolausHerdegen from Siemens (from left toright)

Around 90 percent of the Feinjerseygray cloth is knitted in raw white andis only given its color during finishing.A Terrot machine with a Sitex CKcontroller is shown in the picture

Fein

jers

ey

The Schönherr TextilmaschinenbauGmbH, a company with a long tradi-tion that is a subsidiary of the world

leader Stäubli Group manufactures thedouble carpet gripper weaving machine,the most modern and flexible double car-pet weaving machine in the world. It al-lows high-quality carpets to be made tocustomer demands. The prerequisite foroptimum quality is a highly precise inter-action between all components. The dou-

ble-tier warp beam assembly can take upto eight warp beams. The warp beam rackand thread guide then ensure an exactrunning of the thread without crossing ofthe pile and warp threads. The warp ten-sion is pneumatically regulated and there-fore remains constant the whole time.

The weft insertion takes place by linearguided rod grippers on both sides drivenby a special cam gear. This guarantees aquiet, low wear machine operation.

Highly dynamic and accurate

With a new drive concept, Schönherrachieved high performances and a lowdegree of irregularity. The asynchronousmain drive was replaced by a water-cooledmotor which exploits the machine per-formance much more efficiently. Thismeans the drive can be built smaller. Thenew motor also makes the machine moredynamic, angles can be traveled more ac-curately. This ensures exact filling andshaft movements and keeps the warpthreads taut at all times. ■


18Fabric

CASE STUDY

E veryone knows the colorful little la-bels with the manufacturer logo orbrand name. You find them in al-

most every shirt or blouse collar or on thepockets of jeans but hardly anyone knowshow they are made – that they are wovenand parts of endless strips.

The GEL s.r.l founded in 1997 hasample experience in the manufacture ofthese woven strips. Managing DirectorGianluca Prina is and old hand in the busi-ness with his 50 years experience. Qualityand service provide the basis for the com-pany’s success in Europe and East Asia.

The relatively compact Italian ma-chines simultaneously weave ten labelstrips of 20 mm in width. Up to six weft

colors are possible to create all conceiv-able patterns. The warp selection is im-plemented by a Jacquard machine fromStäubli with which patterns can bechanged quickly and easily.

Flexible and precise

A decisive factor manufacturing of thestrips is the perfect synchronization be-tween the main drive, warp let-off andmaterial pick-off. The necessary control isprovided by Masterdrives MC CompactPlus which are optimally adapted to thesynchronous servo motors 1FK6.

The compact, low-cost Simatic S7-200takes care of the entire I/O management.Simatic OP7 also provides the user with a

Masterdrives provide perfect labels

Labels on endThe Italian company GEL will be presenting machines for manufacturing textilestrips at this year’s ITMA. Decoratively patterned strips will be produced inJacquard technique. GEL has the ideal automation solution with Simatic S7-200and the Masterdrives MC Compact Plus.

well-organized HMI system which allowsintuitive and comfortable operation of themachine.

Siemens therefore provides GEL with alow-cost solution for this complex motioncontrol task. Gel on the other hand appre-ciates having found a strong, globally rep-resented partner for their internationalbusiness activities. ■

Multicoloured woven strips are theresult of a perfect machine andautomation solution

Schönherr’s double carpet weaving machine

New drives for high performance in the carpet factory

From Loom to High-tech MachineThe machines made by Schönherr from Chemnitz, Germany, manufacture awide variety of carpets at high speed. The changeover to an innovative Siemensdrive concept in the double carpet weaving machine Alpha 360 broughtconsiderable improvements in terms of higher speed and greater accuracy.


19SYSTEM SOLUTION

N ew weaving machine concepts areintended to meet the growing de-mand for high quality woven ware

– cost and time effectively. Based on acomprehensive automation solution port-folio, Siemens has the right answer foreach individual customer. The prerequi-site for this is finding the most economi-cal mechatronic equipment while takinginto account the diverse techniques: weftinsertion technique (projectile, gripper,air nozzle), shedding (shaft movement),patterning with Jacquard machines ofvarious kinds and handling properties of such different threads as cotton, silk,monothreads, hard fibers and wire.

Modules as a basis

From now on, it is possible to adapt theproduct range through specific projectwork with the OEM and common marketresearch so that the weaving process isimproved on the one hand and at thesame time new technological solutionsand markets emerge.

Based on a controller for textile ma-chines, the weaving-technological move-ment tasks have been defined user-specif-ically both on the hardware and softwarelevel and implemented in the platformportal of the Simotion control. This firstmodule which determines a basic weavingfunction serves as a foundation for fur-ther automation solutions.

Modules such as the so-called windingcomputer function module (FM) couldalso be integrated in the technologicalobject by splitting the process chain, i.e.eliminating the mechanical functions

linked to the main drive.The winding computer FMensures high-precision ax-is coordination in the repo-sitioning after a threadbreak. The warp and weftdensity, thread tension,binding etc. are convertedinto optimized equivalentaxis drive parameterswhich simplifies changingof the fabric quality.

The new module con-cept has already proven it-self in machines with dif-ferent weaving technolo-gies such as in plastic dieweaving machines withgripper rod weft shot or inprojectile weaving machines for flat fab-rics.

Versatile

Regardless of the machine manufacturer’sphilosophy, the Simotion basic projectruns on different hardware platforms. Nonew application has to be created in Simo-tion either for different machine-technicalrequirements. With standard interfaceswhich can be freely combined and ex-changed, projects which have alreadybeen created can be adapted with little ef-fort to the new object qualities. All sup-plementary units such as color selector,shaft machine, Jaquard machine, forwardwinding machine etc. can be accepted ordeselected. Actuators and sensors are alsostandardized – by bus technology and useof only one standard voltage.

Rejuvenation

Servo and asynchronous axes have alsobeen implemented in mixed mode de-pending on the requirement profile. Inone case only a regulated drive (asyn-chronous warp let-off) is used while allother functions are still derived from themain axis or from direct drives. Here toothe basic technological object was adaptedto the existing machine periphery. Thisrelatively “painless operation” is also rec-ommended for “retrofitting” older ma-chines. ■

The weaving machine goes modular with Simotion

Time to Say Good-byeThe most sophisticated discipline in textile machine manufac-turing – the building of weaving machines – is freeing itself of the vertical shaft: the age of the modular weaving machine hascome. With a system of function modules, a wide range ofcombinations becomes possible.

Fabric

The fabric is wound with a pre-definedtension after weaving

Siemens offers comprehensive solutions – like for this weaving machine

Biaxial machine

Mal

imo


RUBRIK

the advantages of PC and controller: open-ness, flexibility and performance as wellas HMI, PLC functionality, regulatingfunctions and knitting-technological userfunctions. This has the advantage thatfunctions such as weft insert or standingthread/nonwoven threading or the wetknitting process in all its complexity fromnow on can be activated simply by settingparameters in the display and synchro-nized in relation to the main drive of themachine.

The machine is operated by an HMI sys-tem with touch control. The uniformity ofTotally Integrated Automation also guar-antees the modular automation of the ma-chine. This includes the linking to remotedata transmission systems for the pur-pose of teleservice via Webserver or mo-dem. ■

20Fabric

SYSTEM SOLUTION/CASE STUDY

Biaxial machines exploit the flexibility of Simotion

Optimum Solution with a Great EffectWith the increasing demand for knitware, development in the knitting machine industry has picked up an astonishing momentum. In mechatronicstitch-bonding machines like biaxial machines, the technological flexibilitydepends on the efficiency of their control and drive technology. Simotion offers just the right basis for the desired scalable solution with its variety of integrated technological components.

The Chemnitz company Karl Mayer Malimo is famous for its leading-edge machines inthe field of warp knitting technology. Oneexample of the company’s capabilities is thehigh-performance stitch-bonding machineMalimo Biaxial NM 130. The versatilemachine can be used to make textile glassknitware as a basis for fiber reinforcedplastics in the large container and bodymanufacture as well as for ship hulls andwind power stations. In the stitch-bondingprocess the loosely arranged weft andstanding threads are bonded together by a third threat system and form the ideal basisfor biaxially reinforced composite materialsdue to the stretched position of theindividual threads. Both an exact 90 degreesparallel lay and a slightly crossed lay in the

weft can be produced.With the changeover to the PC-based

solution Simotion P350, the Karl MayerMalimo GmbH was able to eliminate the oldchain or belt drives. The control nowoptimally synchronizes all the individualdrives – from the warp to the weft insert.From the needle movement to the rolling ofthe goods, the entire main drive is alsocontrolled exactly by Simotion. ElevenMasterdrives MC drive axes are also in action.

Fast product changes are in demandespecially for highly specialized technicaltextiles. Simotion meets the requirements ofthe textile machine manufacturers’customers. And finally the high stability andlow susceptibility to faults also speak out infavor of the system.

Industries such as geo, automobile,safety or industrial textiles require spe-cial knitting properties with an extreme

load capacity. The warp beam regulationand the take-up beam for example ensurea uniformly high fabric quality. Othertechnological functions can be integratedmodularly in the automation system as re-quired.

The right system for every job

Simotion provides the ideal solution forthe wide range of functional requirementsin the knitting machine sector. The open-ness of the system – in conjunction with amodern engineering system – allows formanaging, visualizing and transferringall machine data in a project.

The Motion-PC is the ideal control es-pecially for biaxial machines. It combines

Successful Stitch-bonding with Simotion Weft carrier Biaxial

Mal

imo


21CASE STUDY

B astian Wickeltechnik GmbH devel-ops, manufactures and marketshigh-technology plant concepts in

70 countries throughout the world. Nowa-days, the requirements for winding tech-nology are high: manufacturers demandcompact rolls that combine as many run-ning meters as possible on a small diame-ter (1200 millimeters have proven suc-cessful). Bastian produces such ultra-densely wound rolls with a combination ofcore drive and perimeter drive. Only withthis technology is it possible to achieve ahighly material-specific winding charac-teristic – tight at the core with an individ-ual decrease in the tensile force over thediameter. This prevents the material fromrubbing while being wound and damag.

Winders of the future

The company has put a new generation ofcarry-drum winders for the non-wovensindustry on the market: with productionspeeds of 600 meters per minute, a maxi-mum fabric width of 5500 millimeters, awinding diameter of 1500 millimeters andup to 60 single webs (minimal webs width50 millimeters).

The winder BWT 206 has made a deci-sive contribution to improving windingtechnology, as Holger Meyer, marketingmanager of the company, explains: “Indi-vidual drives now make it possible to setthe tensile force variably. The windingshaft has a flexure compensation, loadingand unloading, as well as a core drive. For

an optimum build-up of the bale edge, thebale is force-guided throughout the entireprocess, and the winding is done in oneposition from the core diameter to themaximum winding diameter.”

One component – many functions

The automation from Siemens has al-lowed Bastian to realize a high level ofquality. Masterdrive Kompakt Plus drives,for example, ensure an uniform and ten-sion-free winding. At the same time, thecompany only requires one basic func-tional component such as the winding cal-culator to produce the most importantwinder applications with a single projectplan. Once the component structure hasbeen created as a menu, universal func-tion algorithms can be adapted very easilyto the individual plant configuration byparameterization.

The highlight of the winding calculatoris above all its extensive function menufor controlling the winding functions.Since wear-free winding requires a pre-cise tension control, there is direct and in-direct tension control, tension controlthat affects the motor torque and speedsetpoint as well as a diameter-dependentcontroller adaptation. The winding densi-ty can be controlled and speed-dependentfriction compensation can be performedusing frequency polygons. Acceleration

precontrol, tension precon-trol, diameter calculation andstretch compensation roundoff the range of functions. Foruser-specific requirements,free functional componentsare additionally available thatcan be integrated into the ba-sic menu.

The flexible solution satis-fies mechanical engineers aswell as users: once an applica-tion has been created, it canrun on different hardwareplatforms, on the MasterdriveMC and VC systems as well ason special technological mod-ules for a complex winder ap-plication. ■

Flexible solution for progressive winding technologieswith the winding calculator

Efficiently Wound UpEfficiently winding web-shaped materials onto rolls – the Bastian company hasbeen doing this for almost 30 years. The automatic carry-drum winder BWT206 sets standards for inline winding and cutting of non-wovens. The machineowes its high capacity and flexibility to the automation from Siemens, which isbased on standard project planning.

Nonwoven

The Bastian carry-drum winder stand for a new generation of winders

Bast

ian


22Nonwoven

CASE STUDY

Important components of modern non-woven processing technologies arecarding machines and needle looms.

Along with the companies Dilo and Spinn-bau, the Dilo System Group from Ebers-bach, Germany is one of the most well-known manufacturers of such systems inthe world. Their innovative solutions –e.g. DI-LOOP for structuring needle-punched non-wovens or DI-LOUR for fine

needle-punched velour goods – are mile-stones in the application area of flat andstructured needled felts.

In the case of paper-machine felts, thehyper-punch technology developed by Di-lo has become established as a worldwidestandard. The special feature of this tech-nology is the vertical movement of theneedle bar in the direction of movementof the processed material. This prevents

incorrect drafts in the felt and consider-ably reduces the stress on the material. Atthe same time, an increase in the needlingspeed opens up new possibilities for con-figuring the system for disposables.

Spinnbau, another company in the DiloGroup, has done pioneering work in thearea of random card on the card and is considered the inventor of randomcardtechnology. The web formation on the

The Dilo System Group has relied on Siemens technology and support for years

Innovative Concepts forInnovative MachinesWhether for geotextiles, synthetic leathers, filter media, in automobile lining materials, home furnishings orfloor and wall coverings, non-wovens have established themselves among high-tech textiles. Their constantlyexpanding application areas require a continuous further development of the production and processingmethods and the corresponding machines. Dilo System Group, a world-renown manufacturer of machines forthe non-woven industry, has relied on a partnership with Siemens for years, with great success in automationand drive technology.

Needle loom DI-Loom PMF


23

Mr. Dilo, you have been relying on Siemenstechnology for years. Why?Dilo: I am convinced that I have found anextremely experienced and innovative partner inSiemens. The possibility to obtain visualization,motion control and drive technology from onesupplier brings us enormous benefit.

The remote servicing capability of theSiemens equipment is also very important to us.It enables us to perform failure diagnosis andsoftware updates from Ebersbach throughoutthe world. This not only saves us a considerableamount of money for service work but can also significantly reduce our customer's down-times.

You are a global company. What does Siemensoffer you in this respect?Dilo: First, it is not only important for us to beglobally oriented, but for our customers as well.Naturally, we observe this first of all in the area

of support with Siemens. The support is globallyoriented: for example, Siemens ensures us thatpersonnel and spare parts are continously avail-able throughout the world in the framework ofrepair and service agreements.

In Mannheim, Mr. Arnold and his group are a one-stop service contact for Dilo throughoutthe world, right on our doorstep. His strong andvaluable support helps us in all phases, fromimplementation to the day-to-day exchange ofinformation. This is an advantage that we doappreciate greatly.

What do you plan for the future?Dilo: The cooperation with Siemens hascompletely convinced us. For this reason, wewill continue to rely on the innovative tech-nology and the strong support from Siemens.

And we have nothing further to add to that. Mr. Dilo, thank you for the interview.

Dilo

Excellent partnershipWe spoke to Johann Philipp Dilo about his preference for Siemens.

card is one of the most important processsteps on the way to a complete non-wovenproduct. The card thereby lays the founda-tion for the quality of the final product.With the development of hyper-speedcards and the construction of super-widecards (with up to five meters workingwidth), Spinnbau leads the worldwidetrend towards increasingly wider andmore productive installations.

Automation and drive technology from one supplier

At Dilo and Spinnbau, they also know thathigher speeds and throughputs also re-quire a greater operating safety and avail-ability of the individual machines and the entire production line. The machinesfrom Dilo and Spinnbau achieve the nec-essary reliability and safety in particularthrough the use of automation and drivetechnology from Siemens, which is veryimportant for the hyper-speed card ofSpinnbau. Here, the proven Simatic S7-400 controller, supplemented by the ap-plication module FM 458-1 DP, provideshigh dynamics, extensive functionality,high clock rates, fast processing of largeamounts of data as well as the masteringof complicated control sequences in mul-ti-axis drive systems. The system can fur-thermore be freely planned and offers in-tegrated engineering (Step 7), data man-agement and communication as a resultof Totally Integrated Automation.

The Simovert Masterdrives drive sys-

tem (Vector Control and Motion Control),which has also proven its worth especiallyin the area of plant engineering, helps toachieve system characteristics that guar-antee high equipment availability andreliable production numbers for the enduser. The motors of the series 1LA, 1FTand 1FK, which have very good operatingcharacteristics, long service lives and highvoltage- and current-carrying capacities,also make an important contribution.

For operation and monitoring, the ma-chines are equipped with a Simatic PC thattransfers and manages technological andequipment-specific data on a Windows-based operating system. The simple andtransparent project planning tool SimaticWinCC provides the user with a completetool for designing the process visualiza-tion.

The tailored solutions from Siemenswere not the only thing that convinced Jo-hann Philipp Dilo, the managing directorof Dilo and Spinnbau, and his people. Thecooperation with Siemens also played adecisive role. ■

Spinnbau’s Hyper-Speed-Card forhigh-speed card application

Dilo


24Nonwoven

CASE STUDY

F leissner GmbH, with headquarters in Egelsbach, Hessen (Germany), isone of the leading manufacturers of

high-performance production lines forthe nonwovens industry. The medium-sized company has consistently expandedthe nonwoven area since the 1960’s.

State-of-the-art methods such as thewater-jet bonding Aqua-Jet from Fleissnermake it possible to produce compositeswith different weights and characteristics.The new spunlace processes AquaJet,AquaPulp, AquaSpun and AquaSplit areeven capable of producing compound andsandwich fabrics with cellulose fibersand microsegment split fibers.Spunlace fleece fabrics are bothsoft and tough and thereforefrequently applied for do-mestic, medical and in-dustrial purposes.

Economical pro-duction with

high-grade nonwovensqualities is the motto of the company. For this rea-son, newly developed filtersystems and high-capacitypumps extend the mainte-nance intervals and therebylower the operating costs.Fleissner has also devel-oped an optimized nozzle

head: because the water jets are distrib-uted over the entire width of the fabricwith an even pressure, the nonwoven isuniformly bonded. Last but not least, indi-vidual products can be manufactured on

the Aqua-Jet production lines with a mul-titude of different patterns and surfacefinishes. By constantly implementing thedemands of their customers into ideas,Fleissner has made the AquaJet methodinto a success story for six years now.

Efficient communication, high-capacity drives

This would not be possible without a high-grade automation from the controller tothe drive, and up to the sensor. The pro-duction line’s physical extension of up to100 meter (= 328.1 feet) long alone re-quires a high-capacity bus system. SimaticNet Profibus forms the communicationbasis for the entire automation system. ASimatic S7-400 controller controls theproduction line. With the PLC and Profi-bus, booster sets of other manufacturersas well as water treatment plants, sliver,sand, coarse and fine filters can be inte-grated. Simatic WinCC allows everythingto be displayed in a clearly arranged wayon the screen and comfortably operated.

High-dynamical drives like Master-drives VC provide the required power ofseveral 100 kW for the high-pressure wa-ter pumps without any problem. Master-drives VC Kompakt Plus in particularprove their strength as especially precisetransport drives – even with very differentnonwoven materials. The compact andeconomical Micromasters also demon-strate their versatility: as accessory drivesfor auxiliary pumps, fans and filters.

Easy to service and economical

The leading textile machine manufacturerFleissner with its large market share inChina appreciates the reliable and fastmaintenance service of this continuousand modular automation. For service andmaintenance, they have the choice of re-mote maintenance or the local service andsupport offices of Siemens. As a result ofthe uniform solution, they also avoid dif-ferent supplier systems, thereby saving

considerable time and costs while in-creasing the quality at the same time.

Project planning and commission-ing are also simplified. And

last but not least, the endcustomer profits because

less training effort andless stockkeeping of

spare parts is nec-essary. ■

Siemens automates AquaJet production line of Fleissner

Producing NonwovensUnder PressureBonding methods such as water jet technology help to make innovativenonwoven fabrics with wide applications. The AquaJet method of the Fleissnercompany has set standards in this field. With automation technology fromSiemens, Fleissner fulfills the high demands for a large product range, reliabilityand accuracy of the production lines: starting with the Profibus bus system, tothe drive and control system, right up to the software.

Water pours onto thenonwoven from thousandsof nozzles. This entanglesthe fibers and bonds thenonwoven

Flei

ssn

er


25CASE STUDYDying and Finishing

The Cimi company founded in 1963 is located in theheart of the Biella textile industry. Ideal conditionsfor a company with a wide range of products to be-

come a textile refiner renowned all over the world.Textile refinement serves for final treatment of the raw

fabric and can be considered one of the most crucialphases in the production process: It not only makes thefabric more resistant, it also lends it a softness and glean.

Making woolen felt under extreme pressure

A special method of making a woolen fabric more resist-ant is fulling whereby mechanical pressure is applied to a woolen nonwoven fabric which fulls and compacts it. At the same time the area is compressed and the feltshrinks.

Cimi was looking for an innovative technological solu-tion for the fulling and fast washing machine. Four carri-er rollers, the fulling drum with carriage, an airing unit,the spray device for moistening and an offset carriage inthe fast washing had to be fitted with a new control sys-tem.

The Soft-PLC Simatic WinAC MP for embedded systemsproved to be the ideal solution for these data-intensivecontrol tasks. It is based on the Windows CE operatingsystem and unites the function properties of PLC and PCin one unit.

Control and monitoring in one unit

The technological heart of the plant automation isformed by the multifunctional platform Simatic MP370:

It takes care of visualization and control on a single hard-ware platform. To do this, the Simatic Multi Panels (MP)have been extended with the Soft-PLC Simatic WinAC incomparison with conventional operator panels.

This principle is ideal for the fulling machines. Themachine runs through various phases during the re-finement process, every one of which requires a suitableregulation and control. The optimum quality of the endproduct can only be guaranteed by compliance with criti-cal control parameters such as drum pressure, rollerspeed, temperature control and liquid dosing. The refin-er must set special algorithms in WinAC in order for themachine to adapt the parameters automatically to thetype of fabric and degree of fulling desired by the enduser. The Italians can rely on long years of experienceand know-how for this.

The Soft-PLC has high response speeds in order to ful-fill the demanding control tasks. For example the meas-ured values must be recorded at regular intervals in thetemperature regulating system of the Flexifola to guaran-tee the control accuracy.

Space and cost saving solution

But other properties of the functional solution also con-vinced the textile machine manufacturer. The compactdesign reduces space requirements and fast commission-ing is possible thanks to a single hardware component.The company makes further savings by less wiring, lowspare parts stocks and optimized service. ■

Textile refinement plant renewed by innovative Soft-PLC Win AC MP

Quality Felt GuaranteedTextile refinement plays an important role in the manufacture of fabrics. The Italian company Cimi makes great demands on the efficiency and quality of its refining machines. The company is thereforeeager to snap up innovative technological solutions: In the Flexifola fulling machine the system control was implemented with WinAC Soft-PLC and the Simatic Multi Panel MP 370.

Moenus Textilmaschinen GmbH,Gera, unites the well known brandnames Artos, Krantz, Stentex andSucker with more than 150 years ofexperience in the field of textilemachine manufacture under oneroof. The range of products fullycovers the process of weaving prepa-ration and the wet and dry equippingof textiles. More than 150 patents are evidence of the company’s joy ofinnovation. The merger of theseproven services makes Moenus astrong partner for the worldwidetextile industry.

The new high-performance warpingmachine Comwarp, developed un-der consideration of numerous cus-

tomer wishes, is highly suitable for bothstaple fiber yarns and filament yarns. Itcan be optimally adapted to any area ofapplication with V and parallel gates. Themodular concept of the Comwarp allowscustomer-specific equipping for warpbeam diameters of 800/1000 and 1250/1400 millimeters at working widths of1400 to 2800 millimeters. An extensiverange of options such as gluing device,ionization, beam lifting device, operatingplatform, allows optimum adaptation tocustomer requirements. Processing timescan be reduced and availability increasedas a result.

A high-performance machine obvious-ly also needs innovative automation con-cepts. The proven and highly efficient con-trollers of the Simatic S7 series togetherwith Profibus-DP form the backbone ofautomation. Together with the patentedduo-length measuring system they enableresidual lengths below 0.1percent of thewarp set regardless of the number of yarnbreaks.

In order to meet the suddenly growingdemand for Asian characters, the modern,

ed by service personnel in the manufac-turing country.

Because of the high quality demandsand the company principle of always de-veloping the best solution for the cus-tomer, the innovative products of all fourMoenus brands are already being manu-factured and assembled with a view to thestrict regulations of the European stan-dard 8214 (ISO 9000 ff). Long-term qualityassurance and the continuous improve-ment of all services are the ambitiousgoal. In future the Moenus Textilmaschi-nen GmbH will work more closely withsuppliers who also meet these require-ments than in the past. After a trickyphase which the company group survivedwith Siemens as a strong partner by itsside, they can now look forward to meet-ing the challenges of the constantlychanging textile market together. ■


26Weaving Preparation

CASE STUDY

fully graphic-capable Multi Panel SimaticMP 270B Touch was chosen for visualiza-tion and operation. The multi-functionalplatform combines the robustness of anadapted hardware with PC-typical flexi-bility. The industrial compatibility of thismultitalented panel is underlined by itsextreme robustness and shockproof, dust-proof and splashproof housing. Addition-al functions can be added to the systemwithout a hard disk for example for re-mote maintenance and service via the In-ternet/Intranet. The Comwarp takes careof the entire data acquisition, recipe man-agement and shift management in the MP270. The language can also be switchedover online to guarantee it can be operat-

High-perfomance warping machine Sucker Comwarp with Muli Panel MP 270 Touch

Future-proof and Flexible

Graphical visualization on theMulti Panel MP 270B Touch

The high-performance warpingmachine Sucker Comwarp

Moe

nu

s

Moe

nu

s


27CASE STUDY

Modern fabrics repeatedly lead tonew machine developments in textilefinishing. The Swiss companyBenninger, already very successful inthe field of weaving preparation, hasput a washing machine on the marketthat gently processes knitted goods as well as elastic fabric: Trikoflex.Benninger has realized innovative andcustomer-friendly automation solu-tions for this in close cooperationwith Siemens.

The finishing sector is booming in thetextile industry. After all, the cloth-ing industry continually demands

new methods for treating fabric – to giveit color, improve the feel, or to removespinning oils from sensitive elasthane(spandex) materials.

Optimum washing results

After the production process, fabrics haveto be washed in order to remove harmfulelements. Especially mono- and bi-elasticfabrics and knitted goods need gentleprocessing – i.e. the sensitive textile webmust not be pulled. The international Ben-

ninger Group from Uzwil has enjoyedground-breaking successes in this area.

The Trikoflexdrum washing cen-ter makes it possi-ble to shrink per-fectly syntheticfibers (filaments)in particular. Towash elastic fabricsand knitted goods,the goods are trans-ported with lowtension over agrooved drum witha mesh covering. Inthis way, they can-not avoid the hy-drodynamic waterpressure when theypass through thespray section. A center-driven unwindingarrangement at the entry prevents rollingedges. The liquor film that forms on bothsides of the fabric quickly carries away im-purities, and the washing liquor circulatesin two separate liquor cycles. The washingeffect is increased considerably comparedto the standard mesh and screen drums.

The Benninger machines fulfil the mostup-to-date requirements for open-widthprocessing, which scores points especially

with knitted goods. The machines preventrunning creases and give the fabric asmooth surface. Production costs andtime can also be significantly improved incomparison to rope-form processing inlong liquor.

Universally successful

The market success of the finishing spe-cialists is based on optimum process con-trol and intelligent networking of the ma-chines. A universal automation is there-fore the core competence of the company.A competent partner for this was found inSiemens.

Totally Integrated Automation ensuresseamless integration from the PLC up tothe I/O's. In addition to the AC drives, themost important elements of the processautomation in the washing plant are thePLC, the HMI system and the distributedI/O’s. The washing plant is controlled by aSimatic S7 414-2; a Simatic OP27 and a PC670 are for operation and monitoring. TheET200 distributed I/O’s are connected withthe PLC and the drives via Profibus, andinterfaces to higher-level systems makethe equipment flexible for extensions.

Benninger customers especially appre-ciate the possibility of remote mainte-nance. The have direct online access to aBenninger service technician via the PLCand a telephone line. The technician canthen make a qualified diagnosis withouttravel expenses or system downtimes. ■

Dying and FinishingAfter production the fabrics are reused to remove harmful substances

The Trikoflex washing center fromBenninger treats elastic knitware with the greatest care

Post-treatment of textiles optimized with universal automation

Gentle Wash CycleBe

nn

inge

r

Ben

nin

ger


28Dying and Finishing

CASE STUDY

The requirements for textile finishingmachines are high. Since increasing-ly frequent article changes are the

rule in the production process due toshorter yardages, the machines are re-quired to be highly flexible. Short change-over times help the finishers to reactquickly to changed requirements. In addi-tion, the replacement of mechanical sys-tems by mechatronic solutions has provensuccessful particularly in finishing. This is achieved, for example, with drives with

intelligent motion control, such as virtualmasters for “split warp” on stretchers in atechnology package. Here, the drives re-place mechanical solutions; the gear iseliminated.

Clever modularization saves costs

A flexible plant design is indispensable incontinuous textile finishing. Modular ma-chine concepts with a central or distrib-uted intelligence are therefore gainingground.

A distributed automation structure isjust the right thing, in particular for ma-chines with very many drive locations. Inthis case, the machine is split into differ-ent axis groups, which are controlled sep-arately. The great advantage to the cus-tomer is the modularization, however.The formation of modules increases theflexibility for individual customer require-ments and the number of variants of amachine type. Different versions of a ma-chine can therefore be created with only

a few modules. In addition, thecommissioning of the ma-chines is considerably simpli-fied: individual machine partsare completely tested beforeshipping, so that they onlyhave to be linked up on site.

Intelligence in the drives

Textile finishers want a com-pact, flexible and easy-to-scaledrive solution that is simple to implement with a smallamount of engineering. In thetextile finishing industry, thecall for really intelligent driveshas also become louder andlouder – in other words, fordrives that can control the axisgroup of a machine module in-dependently and automatical-ly. In addition to drive control,the drive should also be able toincreasingly take over motioncontrol, logical and technolog-ical functions. With the drive-based motion control systemSimotion D, the drive familySinamics S and the drive in-terface Drive-Cliq, Siemens

Modular machine automation in textile finishing

Smart and InnovativeWhether with knitted goods or fabrics: economic efficiency is the top priority for all finishingprocesses in wet textile finishing. Nowadays, users demand maximum flexibility, optimum profitability and an excellent result along with the best reproducibility from their machinery. Themanufacturers of continuous production lines therefore offer modular machine concepts withincreasingly intelligent drive and automation solutions. As a result, finishers can optimally selecttheir machines and react quickly and flexibly to market changes.

PROCESS FIELD BUS

Simatic S7HMI Simotion ES Process computer

Plant LAN

Power modules

Sinamics S+ Simotion D

Sinamics S+ Simotion D

DistributedI/O

Ethernet

DistributedI/O

The modularity of Simotion and Sinamics supports intelligentdrive control especially in finishing processes


29CASE STUDY

meanwhile offers a universal, modulardrive and automation solution for de-manding multi-motor applications for“continuous webs”.

The decisive components in this decen-tralized control concept are self-sufficient,coordinated functional units such as con-trol electronics, power electronics, intelli-gent motors and motor sensors that areflexibly connected to each other via digi-tized interfaces. The highlight is the useof “electronic nameplates”. Each func-tional unit is electronically identified andis automatically recognized by the system.This makes it possible for the after salesservice to clearly identify and allocatecomponents as well.

The fast and simple engineering isanother benefit of the Siemens solution.Convenient and menu-guided software

In the production of tubular knitted fab-rics, the “preshrinkage” of the fabric isan important intermediate step. Before

material is cut to length and sewed, it firsthas to be shrunk to the right width so thatit will not change any more later.

Well-known companies such as Hanes,Fruit of the Loom and Jockey appreciatethe more than 70 years of experience ofTube-Tex in this field. Since more than 65percent of the machines are destined forexport, the company was looking for anautomation solution that would be easy toservice throughout the world and also ex-tremely adaptable.

Flexible and customer-friendly

The right solution was soon found withSimatic and Profibus. Components fromdifferent manufacturers can also be de-centrally connected to the bus system.PLC programming, engineering and theTeleService adapter are combined in theStep 7 software package and can be con-nected with third-party products viaProfibus.

As the fabric moves through the ma-chine, a Simatic S7 PLC controls sevensynchronized drives that rotate at differ-ent speeds. In order to obtain an optimum

Profibus enables the production of high-quality materials

High-quality for Strong BrandsPolo shirts from Lacoste stay in shape even after being washed many times.The US company Tube-Tex produces textile finishing machines that ensure ahigh quality for shirts branded with the famous crocodile. In these machinesnetworking with Profibus creates the basis for extremely high flexibility and reliability.

Dying and Finishing

preshrink quality, a constant speed ratiohas to be maintained.

Once the machine operator has opti-mized the fabric, the machine settings canbe saved as a recipe. The width monitor-ing and controlled shrinkage of differentmaterials are also managed via the recipeinput. Thanks to Profibus and TeleService,Tube-Tex can now also quickly help far-away customers who work with compo-nents from different manufacturers. In asimple telephone conversation, Tube-Textechnicians were even able to get the ma-chines of a finisher in Pakistan runningagain within a few minutes. ■

tools facilitate project planning, commis-sioning and diagnostics. Above all thescalability of the components is an impor-tant quality criterion for drive products.

“Universally” successful

The market success of the finishing spe-cialists is based on the optimum processcontrol and intelligent system networkingof the machines. Universal automation isa characteristic of future-oriented textilefinishing companies.

The connection of the drive compo-nents to the fieldbus level, the coupling offurther control systems as well as the con-nection of distributed I/O’s takes place viathe clock-synchrinized Profibus. The plantis integrated into the existing operatingnetwork via Ethernet, using TCP/IP com-munication. This consistent networking

reduces the cabling as well as the hard-ware costs for the automation equipmentand peripheral circuits.

The universality of Totally IntegratedAutomation has even more to offer,though: coordinated system componentsconsiderably reduce number of intefaces.The uniform engineering tool ensurescontinuous engineering. It enables a fastdata exchange among components andsimplifies the planning of multi-axis func-tions.

Innovative solutions require compe-tent partners. Siemens has many years ofexperience in implementing developmentprojects together with machine manufac-turers. Siemens will have further detailedinformation on their state-of-the-art, flex-ible automation concepts at the ITMA inBirmingham. ■


30Dying and Finishing

CASE STUDY

The world’s very first digital inkjettextile printer employs the entireknow-how of the Reggiani companyin Bergamo. The aptly namedmachine DReAM convinces with high speed and optimum resolution.In addition to the newly developedinkjet print heads,the considerableperformance of themachine is due tothe drive-basedautomation solutionwith SimovertMasterdrives MC.

The Reggiani Mac-chine S.p.A. canboast 50 years ex-

perience in the prepa-ration and printing offabrics. The productsrange from the flatprinting machine PRI-MA and the rotationprinting machine UNI-CA through the patterntable UNISTAR to the clamping frameTERMA for the pre-treatment and refine-ment of fabrics.

Machine of the future

Innovative ideas are the basis for Reg-giani’s success. With the development ofthe digital fabric printing machine DReAMthe company planned to anticipate marketrequirements with the latest technology.The cooperation with efficient partnerssuch as Aprion Digital and Ciba SpecialityChemicals Inc. resulted in a machine with sensational printing properties. Itssophisticated technology is based on aproven Reggiani transport system which

holds the fabric exactly in position. Syn-chronized with the new inkjet print headsfrom Aprion, the DReAM reaches a speedthat was not previously considered possi-ble: 492 feet (= 150 meters) per hour, at aresolution of 600 dpi and a printing widthof 63 inches (= 1600 millimeters).

The six-color inkjet print heads have512 spray nozzles each. Inks developed

specially for the machine such as reactive,acid, pigment and dispersion inks allow a wide variety of patterns. The loading de-vice for the ink allows cartridges to bechanged without interrupting production.

The equipment of the machine makes itparticularly suitable for making designerfashion articles – even leather can beprocessed without any trouble. In addi-tion, the cost-efficient production ofmedium-sized quantities is possible.

Precise control for perfect printing

To ensure the high quality standard alsoin the automation, Reggiani looked for acompetent partner who also guaranteed

worldwide technical support. The exportpercentage of the company is after all 70percent of the total production. Owing topast good experience, Siemens was con-tracted to supply the electronic compo-nents for the switch cabinet and machine.

In printing machines, a perfect print re-sult depends on exact control of the indi-vidual axes of the printing roller. Simovert

Masterdrives MC hasproven first choice inthis field due to their ef-ficient control and re-liability. The frequencyconverters with brush-less servo motors con-trol the rotation axeswhich are responsiblefor controlling themovements. A linearmotor is responsible fordriving the print head.The asynchronous mo-tors which regulate thetemperature of the drierup to 100 degrees Cel-sius as auxiliary drivesfor example are also con-trolled by converters.

Two Simatic S7-315 2-DP CPUs connectedwith the periphery via

Profibus and AS-Interface are used forcontrolling the machine logic. Communi-cation between the two central units takesplace via Multipoint Interface (MPI).

A PC is responsible for verifying thedata and checking the functionality of theDReAM. The future equipping with tele-service will enable quick intervention overlong distances allowing Reggiani muchgreater flexibility of action. The PC canalso improve the form and color of theprinting results. Thanks to various graph-ic formats such as .tif for example. all theimportant data for the desired appearanceof the print can be transferred by an exter-nal PC. ■

Revolutionary textile printing technology twinned with state-of-the-art automation

Marvelous Printing Results


31PRODUCTS

Sinamics is the new drive series with a common hardware and software base

Productive Platform

With Sinamics, Siemens places its drivesolutions with integrated engineering ona common hardware and software basis.For Sinamics S120, Sinamics G150 andSinamics G110, uniform configurationand commissioning tools create synergiesand efficiency above and beyond the vari-ous family members.

The modular drive system SinamicsS120 is suitable both for single axis andfor multiple axis applications and solvesall drive tasks universally in one machine:With powers of 1.6 to 107 Kilowatt, Sina-mics S120 covers the power range for dy-namic to highly dynamic applications.

Sinamics G150 regulates the speed oflow voltage asynchronous motors withpowers between 75 and 800 Kilowatt. Upto 50 percent less energy and footprint are required, distinguishing the SinamicsG150 from comparable drives. Its ex-tremely simple handling simplifies notonly assembly and operation but alsoservice. The smallest frequency converterfor variable speed drives in the Sinamicsseries is Sinamics G110. It is suitable as

There is an ideal drive solution for plantoperators with weak mains (or high mainsrequirements): Simovert Masterdriveswith AFE.

The high proportion of harmonics usu-ally generated in electrical systems is ef-fectively eliminated by the AFE. Currentand voltage are fed back into the mains inalmost ideal sinusoidal form. The powerfactor cos ϕ can be specified individuallybetween 1.0 and 0.8. An additional equip-

ment for the mains compensation istherefore unnecessary.

The AFE ensures optimum return feed-ing capability especially in weak mains: Ifthe mains fail completely in return feedmode, active switching off ensures that noinverters are tripped. And there is anotherproperty of the AFE which helps to main-tain operation of your system on weakmains: The current converter operates asan amplifier with a higher intermediate

circuit voltage in relation to the peak val-ue of the mains voltage. In this way evenstrong mains fluctuations can be compen-sated and plant standstills avoided.

AFE – An investment which often paysin view of the costs of production failureand mains compensation! ■

Simovert Masterdrives with intelligent feed-return unit

Strong in Weak Mains

240 Volts with a power range of 0.12 to 3Kilowatt. ■

a drive in the food, textile and packing in-dustries for single-phase mains of 200 to

32 PRODUCTS

Simotion integrates motion control, logicand technology functions into a singlesystem. This eliminates the time-criticalinterfaces between individual compo-nents and leads to a more efficient engi-neering. The range of solutions offered bySimotion extends from simple speed con-trol units right up to complex multi-axismachines, where a large number of indi-vidual axes must be designed and put intooperation.

Simotion comprises three separatecomponents: engineering system, run-time software and various hardware plat-forms as the target system. The Scout en-gineering system handles motion control,logic and technology tasks in a single, in-tegrated system. It also provides all neces-sary tools – from programming and para-meterization, through test and commis-sioning, right up to diagnostics. Applica-tions that are created using Scout can berun on any Simotion hardware. The usercan select the most suitable platform forhis particular machine. In full accordancewith the concept of Totally Integrated Au-tomation, the Scout engineering systemrelates to a common database. With itsdownloadable technology functions, theruntime software is both flexible and scal-able, allowing several motion control, log-ic and technology functions to run in par-allel on one control unit. This modularstructure enables the overall functionalityto be tailored exactly to the requirementprofile of the machine in question.

Simotion runs on three hardware plat-forms:

Controller-based Simotion C in the S7-300 design is modular and flexible to use.The PC-based version Simotion P com-bines motion control and visualizationand monitoring features on one platform,and is thus available for more advancedtasks.

The compact, drive-based variety Simo-tion D is already integrated into the drive,making it ideal for distributed automationstructures. ■

Simotion – The Motion Control System for Multiple Axes

One Platform for All

Simotion offers three differenthardware platforms to suit manydifferent applications

Siem

ens

PublisherSiemens Aktiengesellschaft,Automation and Drives Group (A&D), Frauenauracher Str. 80, D-91056 Erlangen, Germany

Group Executive ManagementHelmut Gierse, Anton S. Huber, Alfred Ötsch

Editorial Responsibility in Accordance with the German Press LawPeter Miodek

Responsible for Technical ContentsWerner SchmolkeTelephone +49 (0) 9131 98-2959Telefax +49 (0) 9131 98-11465E-Mail: [email protected]://www.siemens.de/textil

Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate Publishing P.O. Box 3240, D-91050 Erlangen, GermanyTelephone +49 (0) 91 31/91 92-501Telefax +49 (0) 91 31/91 [email protected]

Editorial staff: Dr. Beate Bellinghausen (editorin chief), Robert Engelhardt, GabrieleStadlbaur

Layout: Jürgen Streitenberger, Rainer Degenkolbe

Copy editors: Regina Severing, Olaf Wolff (copy chief), Sabine Zingelmann

DTP: Doess, Nuremberg

Printed by: Wuensch Offset-Druck GmbH,Neumarkt/Opf.

© 2003 by Siemens Aktiengesellschaft Munich and Berlin

All rights reserved by the publisher.

This edition was printed on environmentally-friendly chlorine-free paper.

The following products are registeredtrademarks of Siemens AG:AS-INTERFACE, ET 200, MASTERGUARD,MICROMASTER, MP370, SCOUT, SIEMOSYN,SIMATIC, SIMATIC S7-200, SIMATIC S7-300,SIMATIC S7-400, SIMOTION, SIMOVERT,SINAMICS, SINUMERIK, SITEX, SIVACON,TOTALLY INTEGRATED AUTOMATION (TIA),WinCC

If trademaks, technical solutions or similar arenot included in the list, ist does not imply thatthey are not protected.

The information provided in this magazinecontains merely general descriptions orcharacteristics of performance which in caseof actual use do not always apply as describedor which may change as a result of furtherdevelopment of the products. An obligation toprovide the respective characteristics shallonly exist if expressly agreed in the terms ofcontract.

Order No. E20001-A250-P620-X-7600

Siemens offers a wide range of gear motors

Geared up for All Drive Tasks

Siemens offers a full range of gear motorsfor a wide variety of drive tasks: from heli-cal through offset shaft and bevel up toworm gearboxes. Thanks to the modularassembly concept the motors can beadapted to requirements by adding on en-coder, brake or external fan.

Helical gearboxes have a coaxial struc-ture and offer various assembly possibili-ties with their housing design as a flangeor mount version. Offset shaft gearboxesrecommend themselves with their com-pact and good geometry as the optimumsolution for space-saving drive tasks. Bev-el gearboxes are angular gears and aretherefore suitable for the most difficult in-stallation conditions. The low-cost wormgearboxes are also angular gears but witha lower efficiency. You will find further in-formation and technical data at:

www.siemens.com/gearedmotors

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