// projects / hmi
HMI SystemServo traverse and VFD spindle synchronised by PLC — multiple hanks wound evenly in a single automated run.
HMI SCREEN — FISHING LINE WINDER CONTROL & PARAMETER SETUP
// the_challenge
Producing consistent fishing line hanks requires precise coordination between two separate movements: the traverse mechanism, which distributes the line evenly across the width of the hank, and the winding spindle, which pulls the line at constant speed. If these two movements are not synchronised correctly, the windings pile up at the edges or bunch unevenly in the middle — producing a hank that is difficult to unwind in the field and fails quality inspection.
Our automation system controls the traverse axis using a servo motor for precise, programmable position control, and the spindle using a VFD-driven induction motor for smooth, adjustable speed. A PLC coordinates both axes based on parameters entered on the HMI — hank width, winding pitch, spindle speed and the number of hanks per run. The system automatically winds multiple hanks in a single operator setup on a custom-designed multi-hank take-up roller, reversing the traverse direction at the correct point and advancing the roller to the next hank position when one is complete.
// capabilities
A servo motor drives the traverse carriage under PLC position control. The pitch (line-to-line spacing per revolution) is calculated by the PLC and applied to the servo profile — ensuring even winding at any speed.
The take-up roller is driven by a VFD-controlled motor. Spindle speed is set from the HMI and maintained constant throughout the run, compensating for increasing roll diameter via a dancer or tension feedback option.
The PLC continuously coordinates traverse position and spindle speed. Any change in spindle speed automatically adjusts the traverse velocity to maintain the programmed winding pitch — no manual recalibration required.
The operator sets the number of hanks and presses start. The PLC winds one complete hank, pauses, advances the roller to the next position, and resumes — repeating until all hanks in the batch are complete.
Hank width, winding pitch, spindle RPM, number of hanks per batch, start and end dwell time are all configurable from the HMI touchscreen. Parameters can be saved as recipes for different line grades.
The HMI displays a real-time hank count and estimated completion time. A hardware emergency stop halts all motion immediately and holds the servo in position. Resuming after an E-stop restarts from the interrupted hank.
// technology
Need a custom winding or motion control system?We design and build bespoke PLC/servo automation for manufacturing processes.
