PRJ
Flame Laminating Line
Flame Lamination; is a high-precision manufacturing process based on the principle of bonding materials with different levels of flexibility and thermal characteristics—such as foam, fabric, film, and lining—by melting the foam surface using flame burners. In this project, I was responsible for the end-to-end design, programming, and commissioning of the entire electrical, automation, torque/tension control, and drive braking infrastructure, independent of the line’s mechanical layout.
🌟 The Machine’s Operating Principle and Process Architecture
In fact, as the flexible materials enter the machine and pass under the precise burner flame, the micron-level surface of the melted foam transforms into an adhesive layer and is laminated onto the base fabric or film by the cylinder pressing unit.
To ensure this process runs smoothly:
- Warps (Unwinder) Group: It ensures that the raw material is fed into the line without deviating from the path or causing fluctuations.
- Flame / Burner & Melting Zone: The process ensures that the surface is heated uniformly and that the ideal bonding temperature is reached without the risk of combustion.
- Lamination & Press Group: It is the point where the molten surface and the other material are joined under precise torque and pressure.
- Sarğı (Rewinder) Grubu: This is the final stage in which the laminated product is wound onto a reel without creating internal stress or distorting its shape.
🛠️ Engineering Contributions and Technical Details I Provided
1. Precise Pressure and Torque Control Algorithms
- Ongoing Stress Management: PID-based tension control loops were designed to prevent stretching, wrinkling, or thread breakage in flexible and stretchable materials during the bonding process.
- Warp/Weft Dynamics: As the diameter of the reels changed, the motor driver parameters were dynamically updated to account for the varying inertia and torque requirements, thereby maintaining a constant tensile force.
2. Design of Regenerative Power Electronics and Braking Infrastructure
- Termal Hesaplama ve Direnç Seçimi: Ohmic and power calculations were performed to safely dissipate the high regenerative energy resulting from the warp and tension motors operating in continuous braking mode.
- Hardware Optimization: To prevent overheating and extend the panel's service life 400 Ohm / 400–500 W alüminyum kasa frenleme dirençleri tercih edildi.
- Topoloji & Güvenlik: Sürücü DC bus hatlarına entegre edilen direnç gruplarının seri/paralel bağlantı topolojileri simüle edilerek sistemin aşırı gerilim (overvoltage) hatasına düşmesi engellendi ve donanım koruması sağlandı.
3. PLC, Sürücü Entegrasyonu ve Saha Devreye Alma
- Hız Senkronizasyonu: Alev brülörü ile malzeme geçiş hızı arasındaki lineer ilişki otomasyon yazılımına entegre edilerek, hattın yavaşlama veya hızlanma anlarında malzemenin yanması veya soğuk yapışması önlendi.
- Saha Testleri & Entegrasyon: Tüm sensör geri beslemeleri (encoder, dancer/loadcell sensörleri) PLC mimarisine entegre edilerek gerçek hat koşullarında devreye alındı, pano içi termal dağılım doğrulamaları yapıldı.
💻 Kullanılan Teknolojiler ve Yetkinlikler
- Otomasyon & Yazılım: PLC Programlama, PID Kontrol, Hız/Tork Senkronizasyonu, Sensör Entegrasyonu
- Güç Elektroniği & Sürücüler: AC Motor Sürücüleri (VFD), Rejeneratif Frenleme, DC Bus Yönetimi, Direnç Topolojileri
- Elektrik & Pano: Pano İçi Termal Yönetim, Güç Hesaplamaları, Endüstriyel Saha Güvenliği