Customer Background

Founded in the 1950s, this company is a global leader in the plastics industry, with a diversified business portfolio spanning petrochemicals, plastics, electronics, textiles, and energy. Their carbon fiber precursor products are widely used in medical, aerospace & defense, filtration, environment, transportation, communications, construction, and sports & leisure industries, providing high-performance materials for critical applications.

Customer Challenges

As the existing factory equipment aged, production efficiency and product quality were affected. The customer decided to upgrade their production line by implementing a modern control system. Based on their successful past collaboration with YATEC, they selected YATEC as their trusted partner because of its stable product quality, excellent service, and professional technical support.

Project Goals

1.Enhance Production Efficiency – Implement precision control technology to stabilize the fiber drawing process and reduce production errors.

2.Improve Product Quality – Ensure consistent fiber drawing speed to reduce defects.

3.Enable Data-Driven Production Management – Deploy a SCADA monitoring system for comprehensive production data recording and quality monitoring.

Solution

To meet the customer’s fiber drawing process requirements, YATEC provided a comprehensive solution integrating Yaskawa and TECO technologies. Given the harsh factory environment, all equipment underwent strict quality control from design to installation, commissioning, and testing, ensuring high reliability and stability in 24/7 high-speed, heavy-load operations.

  • Yaskawa IE4 Permanent Magnet Motor – Delivers high-efficiency performance, reducing energy consumption and enhancing operational stability.
  • Yaskawa CP-215 Inverter & Control Panel – Ensures consistent extrusion, stretching, and drying speeds. Features redundant PLC and communication network architecture to prevent production interruptions due to communication failures.
  • Yaskawa CP-3550 PLC – Provides high-performance logic control, ensuring synchronized operation across all processes.
  • HMI (Human-Machine Interface) – Enables real-time monitoring and data visualization with an intuitive user interface.
  • Sensors – Accurately monitor key parameters such as pressure, temperature, and tension during production.
  • SCADA Monitoring System – Records real-time production parameters, supporting quality analysis and process optimization.
  • DC Capacitor Power Compensation Panel – Prevents power fluctuations from disrupting production.

Key Solutions for Core Processes

1.Drying Furnace & Gear Pump

  • Torque Compensation – Maintains consistent tension during acceleration and deceleration, preventing material deformation.

  • High-Precision Torque Control – Uses Yaskawa LV1H inverter with a speed feedback card, achieving 150Hz torque response and torque linearity within 3% to ensure stable unwinding and prevent tension fluctuations from affecting fiber quality.

  • Vibration Control – Reduces mechanical vibrations, ensuring fiber quality stability.

2.Stretching Machine & Extrusion Roller

  • High-Precision Speed Control – Provides soft start and torque compensation, ensuring smooth acceleration and deceleration during fiber stretching for consistent quality.

  • Tension Control – Ensures uniform fiber tension, preventing irregularities in the drawing process.

3.SCADA Monitoring System Integration

  • Real-Time Production Monitoring – Tracks temperature, tension, speed, pressure, and other key indicators, ensuring stable production and data-driven decision-making.

  • Fast Issue Identification – Quickly analyzes quality deviations and identifies the root cause for immediate process optimization.

Results

Following YATEC’s system upgrade, the new production line not only achieved its production capacity goals but also successfully optimized manufacturing efficiency.

Additionally, the system incorporates a DC-COMMON BUS design, allowing energy recovery to be redistributed to other equipment, maximizing energy savings.

With the SCADA data-driven management system, management can monitor production status in real time and make quick adjustments. Troubleshooting time has been reduced from hours to minutes, significantly improving line efficiency.

Customer Feedback

"YATEC’s streamlined system makes maintenance easier. When a malfunction occurs, the built-in diagnostic function quickly pinpoints the issue, allowing for rapid troubleshooting and higher production efficiency."