PCT Engineered Aluminum Paint Line Upgrade User Manual

Aluminum Paint Line Upgrade

The Application

An aluminum manufacturer of building and
construction industry products had experienced
strip-tracking difficulties resulting in line
“crashes” and poor strip quality on its 22-year
old paint line. A crash not only took the line out
of production, but also resulted in a large
amount of scrap material. Recovering from a
crash is a time consuming operation. Outdated
equipment made it difficult to make process
improvements. An engineering study identified
the need for improved tension control in order
for the line to resume running at its original
design speed.
The overall project consisted of several smaller
projects that were a combination of:

• Electrical controls upgrade

• Mechanical modifications

• Integration of purchased subsystems

• Installation planning and execution

Implementation of these improvements had to
be made with minimal disruption to the
production schedule.

© 2006 PCT Engineered Systems LLC. All Rights Reserved

The PCT Solution

PCT was asked to replace the paint line’s
existing bridle roll drives, motors and
gearboxes in order for it to operate with
improved tension control.
In addition, PCT provided:

• Programming of a new controller to
integrate the new drives into the
existing line control.

• Reassignment of the master bridle
function to improve tension isolation
between line sections.

• Mechanical and electrical design and
installation of four load cell systems
for tension feedback and monitoring.

• Mechanical and electrical installation and
commissioning of two ultrasonic coil diameter
sensors located at the payoffs and control units
for sensors located at the payoff and control
units for the rage brake and unwind tension
control.

• A new center guide system for the rewind
mandrel to improve wrapping accuracy and to
accommodate increased line speeds.

• Specification and installation of a new hydraulic
unit to meet performance requirements of the
new center guide system.

• As a result of past relationships developed

• PCT provided the engineering, design,

• The aluminum manufacturer’s plant manager is

during cooperative projects, PCT was able to
partner with Rockwell Automation for the paint
line upgrade. PCT saw partnering as a way to
reduce development time, minimize risk and
provide comprehensive commissioning
support. Rockwell’s Drive Systems group
provided a key portion of the tension control
and the GTS group was involved in startup of
the project.

hardware and documentation necessary to
install new DC drives, DC motors and gear
reducers. The new drives were installed in the
existing drive control cabinets in order to keep
project costs down. New motors and gear
reducers were supplied with the necessary
coupling and mounting bases allowing for
easier installation in the existing bridle
locations. PCT also provided programming,
tuning and commissioning of the new drives
and motors.

pleased with the process improvements that
PCT’s engineering team provided within a short
and demanding project schedule. Improved
tension control resulting in the reduction of
strip-tracking difficulties has improved product
quality, and has allowed the paint line to meet
and exceed production expectations.

5433 Tremont Ave.
Davenport, IA 52807

563.391.8011
FAX [phone]

The Solutions Team

© 2006 PCT Engineered Systems LLC. All Rights Reserved

www.teampct.com