Lingchen PLC Infuses Intelligent Power into Spin-Forming Hemming Equipment

In the field of industrial automation equipment, high-precision and highly stable control solutions are critical to achieving efficient production. Recently, Lingchen Technology successfully developed and delivered a comprehensive PLC and servo system solution for a client's "Automated Spinning and Hemming Equipment for Truck Air Brake Valves." Demonstrating exceptional performance and robust stability, this solution successfully replaced imported machinery, thereby empowering the client to reduce costs and enhance operational efficiency.

Project Background and Challenges

The spinning-edge curling equipment previously utilized by this client was supplied by an Italian manufacturer. Although capable of meeting basic process requirements, the system suffered from significant drawbacks—including high cost, lengthy lead times, a high failure rate in the servo system, and substantial maintenance expenses—which severely compromised both production efficiency and equipment stability.
The client's new equipment is required to satisfy the following core process specifications:
1. Cycle time: ≤ 15 seconds per piece
2. Adjustable spinning pressure range: 2%–5% of the motor's rated torque
3. Spinning depth: 20 mm; Spinning speed: 5 mm/s
4. Rotational speed: 200–300 rpm
Furthermore, the project presents several complex control challenges, such as the need for precise calibration of the spinning angle, speed synchronization to prevent overloading, and stringent requirements for the coordination of operational movements.

Lingchen Solutions

To address the aforementioned requirements and challenges, Lingchen Technology has delivered a comprehensive electrical control solution centered on its proprietary PLC, integrated with a high-performance servo system. This solution encompasses a complete service workflow, ranging from hardware selection and program design to on-site commissioning.
1. Precise Electrical Control Solution
Based on complex process requirements—such as multi-axis coordination, switching between torque and position control modes, and the synchronization of high-speed spinning with slow-speed feeding—the Lingchen team has designed robust and reliable control logic. This ensures that the spinning process remains smooth, highly precise, and consistently repeatable.
2. High-Performance Servo System Support
The servo drive system features exceptional responsiveness and overload capacity, effectively preventing alarm-triggered shutdowns caused by speed mismatches during the spinning process, thereby enhancing the overall operational stability of the equipment.
3. Rapid Delivery and Efficient Service
In contrast to the delivery lead times of several months typically associated with imported equipment, Lingchen has significantly shortened the cycle from solution design to equipment delivery. Furthermore, the company provides localized, rapid-response support services, thereby substantially reducing maintenance costs and minimizing losses resulting from equipment downtime for its clients.

Solution Highlights and Summary

This project not only successfully met all of the client's requirements regarding equipment performance but also demonstrated Lingchen's comprehensive technical capabilities in the field of non-standard automation:
Complete Import Substitution: The system rivals the original Italian equipment in terms of control precision and operational stability, while achieving a significant cost reduction.
Flexible Adjustability: Parameters such as pressure, speed, and depth can be flexibly configured via the Human-Machine Interface (HMI) to accommodate various product models.
Convenient Maintenance: The modular design, combined with a clear electrical control layout and wiring scheme, facilitates long-term maintenance.
Continuous Optimization: Even after the project's formal conclusion, Lingchen continues to provide follow-up support—analyzing and summarizing issues encountered during commissioning to implement systematic optimizations and continuously enhance the maturity of the solution.

Moving forward, Lingchen Technology will continue to deepen its expertise in motion control, providing clients with cost-effective, highly reliable, and rapidly responsive system solutions to help them fulfil their equipment upgrade, domestic localization, and automation retrofit needs.