Chain Packaging


The precise manual packaging of a pre-set length of chain can be a tedious and labor intensive procedure. Technical Systems thus designed and developed an automated chain packaging machine prototype which HmT Mechatronics was in charge of automating.

This machine automatically pulls the chain from a bobbin and clamps it with an electromagnet. A reflective laser sensor is used to detect the clamping position and also for quality control data while a rotary encoder is used to measure the amount of chain. Pneumatic cylinders are then used to transfer the chain to the mandrill which contains a permanent magnet. This mandrill motor is used to wind the batches of chain into rolls. Once at the preset length, a pneumatic punch breaks the chain after it was held at an exact angle by another cylinder and the clamp. All the interaction, control and data feedback of this machine is done via the HMI.

Auger Control Upgrade


Technical Systems approached HmT Mechatronics to assist them in the re-design and retrofit of one of their five auger machines. Although mechanically the machine was still in a good condition, the electrical control system’s lifetime has come to an end and needed to be replaced with a more advanced and accurate control system.

Raw material from a bobbin is fed into the auger machine by a series of SEW gearboxes connected via belt drives onto a 15kW AC motor. This motor’s speed and torque is controlled by an equivalent Yaskawa VSD. The head motor (also Yaskawa) allows the operator to change the produced auger’s pitch and diameter by the forward and backwards movement of it. The produced product is then fed into a pipe system containing two sensors calculating the ratio between the raw material used and product produced. The system caters for; recipe selection, alarm list, user setup, total production and service intervals.

Roller Plate Bender


This project was a retrofit of an old machine that was mechanically overhauled. HmT Mechatronics got involved by calculating the different torque requirements as well as specifying required equipment. The motor and VSD had to be capable of rolling 6mm thick sheet metal into cylindrical forms.

To control the machine, 2x foot paddle switches in conjunction with 2x e-stop rope switches wired up to a WEG CFW11 VSD acted as the control system. One foot switch is for forward, other is for reverse.

Grinding Wheel Test Bench


When buying a new grinder blade, one needs to be sure that the blade won’t burst under pressure at any given speed below design specifications. HmT Mechatronics, working with Grinding Techniques, designed and produced a testing machine to test 52 different kinds of grinder blades.

A 7.5kW motor is used to turn/spin the grinder blade at extreme speeds (max 30 000 rpm) via a pulley ratio of 7.2/1. From a laser sensor mounted next to the turning blade or wheel the PLC is able to detect the exact speed at which the disk starts to shatters or burst. This RPM reading is determined by using a feedback encoder mounted at the back of the induction motor. The PLC’s high speed counter counts every revolution and by means calculates the corresponding RPM of the disk. A VSD was used to produce a long ramp-up/down time.