We use cookies to provide you a better user experience and to show you relevant information. If you’re OK with that, just continue. To find out more about the cookies, please read our Privacy & Cookie Policy.
A custom made reinforced foam kit line was not working despite the customer’s and even the manufacturer’s efforts
Instead of trying to fix the existing automation, BTU-TECH decided to set up a new automation.
A unique custom made automation system and renewed electrical cabinet with a new controller and HMI.
An old fabric batching device at customer’s site was not able to batch jumbo rolls due to its mechanics and process control parameters in its software.
BTU-TECH decided to adapt its proven winding software and hardware to the winder.
The new software, supported by additional sensors and completely new electronics including controller, HMI, drives and motors, ran perfectly on the old winder so that the customer could achieve jumbo rolls on the line without having to invest in a new winder.
An old foam slicer was not working despite the customer’s and even the manufacturer’s efforts.
Instead of trying to fix the existing automation, BTU-TECH decided to set up a new automation.
A unique custom made automation system and renewed electrical cabinet with a new controller and HMI while preserving the old drives and motors for min cost.
A fabric kitting company needed to kit certain lengths of glass fabrics for wind blade manufacturer, precisely and in high volume.
BTU-TECH brought together its expertise of winding, sensors and automation.
BTU-TECH developed a highly automated short roll winder with minimum operator intervention and working with high precision of length (+-1mm in 20m), exceeding wind blade standards.
A glass fabric kitting company had problems of fabric feeding to their CNC cutting table, causing wrinkles and/or tensions in the kitted fabric.
BTU-TECH analysed the CNC Cutting machine’s electronics and software and adapted its winding/unwinding technologies.
Result is a roll feeder which works with the CNC cutting machine in perfect harmony (without modification to CNC software or hardware) so that there is not extra tension or loosenes which may effect the cutting process.
A glass fabric kitting company was racing with time for productivity and needed new technologies or machines for improvements.
BTU-TECH analysed the production processes and the related machineries and identified one of the bottlenecks which is halt of the CNC cutting machine during the pickup of the cut fabrics on its table.
BTU-TECH developed a conveyor feeder that works in synchronicity with the CNC and transfers the cut fabrics onto its belt so that CNC cutting machine keeps cutting non-stop while the operators pick up the cut pieces in the additional conveyor table.
A glass fabric kitting company for wind blades needed a complex solution to decrease the man hour and increase productivity. Several fabrics of different lengths were wound manually by hand on paper core tubes.
BTU-TECH analysed the process, all variants and future scenarios to answer all current and possible-in-future needs.
BTU-TECH developed the “MultiRoll” that can can unwind several rolls, at different lengths and times, then cut and wind them on a single roll so that you have several fabrics on the same roll, in different lengths and different positions as well. All done in an automated style. The process required 4 different machines and approximately 15 operators to complete the job. The MultiRoll does all the process in a single line without any operator.
A fabric kitter was spending too much time in transferring rolls between lines and also experiencing safety issues while placing heavy rolls into the safety chucks.
BTU-TECH focused on safety and also precision in the connection of the shaft into the chuck.
BTU-TECH developed a Autoloader-Unloader for airshafts that doesn’t allow manual intervention and ensures the connection of the shaft in the quickest time possible and in full safety.
A glass fabric kitting company had a time consuming tape kitting process where 4 operators cut tape fabrics, positioned them onto each other and stitched them manually on a long table.
BTU-TECH did not only focus on automation but also decreasing the space of production.
BTU-TECH came up with an innovative “Multilayer Stitching Line” solution where all tape rolls are placed on a special rack from where they are unwinded and then stitched together and on a separate rack re-wound as a single roll, all in control fashioned.
A carbon multiaxial producer had a big problem of paper waste & cost that was used as carrier in offline carbon spreader line.
BTU-TECH analysed the used paper rolls, the contamination on It and specs of the paper to develop an unwinding, cleaning and winding back machine to get back perfect and new rolls again.
The result was “Paper Rewinder” that unwinds the used paper rolls with carbon dust on them in a tension control mechanism, cleans it with brush & air, then rewinds with great precision and alignment so that the same roll can be used again and again, allowing big savings to the company and benefit to the natural resources.
A multiaxial glass fabric manufacturer had old lines which also had old hook conveyor pins that holds & carries the layed glass layers until the stitch head. The deformed or broken pins caused gaps in the fabrics and led to 2nd quality materials.
BTU-TECH had to develop a sensor system not only to detect and log the deformations but also work integrated to the multiaxial line.
BTU-TECH created the “industry-first” sensor system for detection, logging of pin deformations and apply the QA protocol defined by the customer either stopping the machine to change the pins or continuing but logging the deformations and breaks.
The reinforcement manufacturer had an old generation multiaxial line which had a take-up system with mechanical coupling that made it difficult and manual to adjust the tension of critical fabrics with high quality criteria.
BTU-TECH had to not only make a mechanical upgrade but also a separate software and control box to solve the problem.
BTU-TECH developed the “Take-Up System” that includes a very precise driving motor that works integrated to the transport chain of the multiaxial line and which also had a separate control box for manual adjustments when needed. The system became fully automated preventing unexpected tension problems.
A wind blade manufacturer needed a special cutting machine for glass fabrics which were used in monolithic parts of the blades to include many layers overlapped and creating an unwanted extra laminate thickness.
BTU-TECH were guided to make a working simple solution but also being cost-effective.
The end result was the “Chamfer Cutter” that precisely cut the glass fabrics with a certain angle so that its thickness was going down to zero from its original thickness allowing two layers overlapping on the thinned section with no extra thickness in the laminate.
A composite materials distributore already had a roll slitter in-house for tape customers but the slitter was not reliable, had low capacity and did not have the sophisticated controls.
BTU-TECH carefully analysed the problems of the existing machine and listened to customer’s needs and expectations before building the “right” machine.
With an agile response, BTU-TECH developed the “Roll Slitter” with the right design. Fully automated, safe, reliable, easy maintanence, operator friendly user interface.
The fabric manufacturer customer produced fabrics at variety of widths depending on customer requests which led him to cut paper tube cores with a simple cutter but deteriorating the quality of the paper core and leading to other problems.
With a limited budget, BTU-TECH had to develop a smart, simple and cost effective core cutter.
BTU-TECH developed a semi-automatic design allowing the operator to cut any length and diameter of tubes without a metal shaft, thus making the design unique among the paper core tube cutters.
A reinforcement manufacturer needed a special coating line to apply adhesive on their fabrics.
After hearing the customer’s needs in detail, BTU-TECH adapted its unwinding & winding know-how but also designed integration of the 3rd party’s adhesive dispensing technology and light fixing to the line.
The result was a complete coating line including the unwinding of the control, coating, fixing, adding of release paper and winding at the end. The whole system worked perfectly in harmony.
A core kit manfacturer for wind blades were marking their core kits with pens and manually. This was not only time consuming but also led to unreadable info as well.
Since big size CNC labelling tables cost a lot with their expensive ink-jet heads, BTU-TECH had to develop a smart and affordable solution.
The result was a “Core Kit & Panel Printer” which worked as a plotter with a very simple CNC mechanism and also was able to incorporate the very same boardmarker pen as the writing tool so that the customer avoided expensive and complex ink-jet heads.
The multiaxial fabric manufacturer who mainly produced jumbo rolls for wind blades, were dependent on one winder brand for the perfect and accepted rolls by the industry. They needed an alternative.
BTU-TECH reviewed the “science” of winding from scratch and all current winding technologies in the industry.
The result was the most advanced “All-in-One Winder” in the industry that included all sophisticated controls and was able to run in all winding modes to batch the perfectly tight rolls coming out of multiaxial lines. Patented loadcells in the surface winders are the core of this sophisticated winding technology.
We use cookies to provide you a better user experience and to show you relevant information. If you’re OK with that, just continue. To find out more about the cookies, please read our Privacy & Cookie Policy.