BTSR International, a company known worldwide for designing technological solutions and developing innovations in a wide variety of industrial areas, has presented Minitron – Megatron – Gigatron, three models of an innovative solution in the field of constant wire tension feed devices.
The new devices, which aim to stand out in terms of functionality and performance, are able to precisely regulate wire tension in motor and coil winding processes.
The Minitron – Megatron – Gigatron solution is based on BTSR’s patented dual control feed system, tension profiling function and dual loop control system, which brings measurable benefits in terms of quality control and production efficiency in coil winding processes.
With this solution, BTSR International has focused on top quality standards, ensured by the quality and repeatability of reel winding, thanks to BTSR’s ‘Double Closed Loop’ technology,’ which guarantees accurate and precise wire tension control.
Versatility is ensured by fully programmable parameters according to wire requirements and the possibility of dynamically changing the control tension of the wire according to the operating phase (Tension Profiler function).
Production efficiency is improved by drastically reducing wire breaks.
Top productivity is ensured by the ability to work at the highest possible process speed.
Labour costs are minimised thanks to user-friendly programming options and the absence of consumable parts. Maintenance tasks are also facilitated.
Thanks to the wide range of wire tensions and diameters of the Minitron – Megatron – Gigatron, wide application areas are possible.
Centralised programming and monitoring is possible thanks to the Matrix Touch Coil controller, which allows the Minitron – Megatron – Gigatron units to be programmed and controlled and the production status of the entire process to be monitored graphically. It allows the logs of each individual wrapped product (coil or motor) and their quality parameters to be stored: wire tension, motor torque, length of wire absorbed (LWA).
Innovative and patented features
Some of BTSR’s innovative features are patented. One of them is the tension profiling function. Thanks to this feature, it is possible to program up to three different wire feed tension values without any interface/connection to the winding machine or up to 4 different wire feed tension values during the winding cycle, using two digital outputs of the winding machine.
A second BTSR patent is the double closed control loop system. The input voltage variation driven by the motor torque and the output voltage variation driven by the motor speed can be controlled using the Dual Control function for a complete analysis of the feed voltage along the entire wire path (from the feed coils to the final wound product).
The third patent concerns the programmable wire storage and release capability. Thanks to this functionality, it is possible to manage the sudden absorption or release of wire, during the work, while simultaneously maintaining the wire supply voltage at the set value.
A fourth BTSR patent refers to full input digital motor torque control. This feature enables the detection and regulation of input supply voltage anomalies (programmable motor torque alarm tolerances), alerting the user and stopping the process before the wire can be damaged, thus avoiding poor quality production.
Finally, collecting uniform data to monitor the entire production, ensuring consistent data collection even with a winding machine fleet that is partly new and partly old, is a strategic move for companies. The PC Link Web Coil software makes it possible to collect the winding tension parameters of each coil, thus certifying the quality of the winding, tracking and storing the data for each motor produced, charting the input/output tension/wire speed values of the cable.
The Pp Link Web Col system is based on Web Page technology, which allows access to data via smartphone, tablet or PC. This allows access via Web from remote locations to monitor the various production facilities.
Multiple benefits
There are many benefits for users who make use of the Minitron – Megatron – Gigatron solution. One of them is the maximisation of the efficiency of the production process. The ability to control the working speed and the working ramps, helps to reduce cable breakages and scrap, guaranteeing a rapid return on investment (ROI).
Another plus is the ability to cover a wide range of cable tensions and diameters.
Programming options were designed to be user-friendly. In addition, emphasis was placed on a power supply technology designed not to damage mechanical parts in any way. The absence of damage from friction or breakage allows for easier maintenance.
The advanced graphic display allows real-time monitoring of parameters such as: Wire Speed (LWA) – Real time Wire Tension, TI motor Torque Index, IQ tension Quality Index Working phase, Arm position. Easy installation, plug & play.
Further features of the high load positive feeder Minitron – Megatron – Gigatron
The three models differ in the voltage range of the display. For the Minitron it ranges from 0 to 5,000 grams, for the Megatron from 0 to 10,000, and for the Gigatron from 0 to 20,000. The programmable voltage range is 50 to 4,000 grams for the Minitron, 100 to 9,000 for Megatron, and 200 to 18,000 for Gigatron. Depending on the model, the range of wire diameters also changes.
For all products, the feeding speed range is similar, as is the LWA resolution (1 mm), the minimum Air Pressure (4 bar) and the power supply voltage. OEM machine computer interface possibilities through SMDIN Web Coil is also similar in the three models (standard: RS485, Canbus; optional: Profinet, Ethernet IP, Ethercat or other on request).
The weight is 10.2 kg for Minitron, 11.8 kg for Megatron and 14.3 kg for Gigatron.
