High-Speed Flying Shear CNC Controller Retrofit
Retrofit an obsolete motion controller with a high-speed Mitsubishi servo amplifier system and electronic camming, cutting hot steel rebar at 18 m/s with ±1mm cutting accuracy.
Operational Bottlenecks & Failure Modes
A steel re-rolling mill producing 500 tons of 8mm-32mm deformed bar daily suffered recurrent cutting inaccuracies on its finishing line. The legacy European shear controller frequently drifted, producing cut bars varying by up to ±35mm. This forced downstream manual re-shearing and created substantial high-value scrap waste. The mechanical shear carriage also suffered violent jerk during deceleration.
System Retrofit & Modernization
IASBD automation engineers replaced the entire motion control section. We installed a Mitsubishi high-speed motion controller paired with a 37kW AC servo drive system and heavy-duty hollow-shaft incremental optical encoder tracking the hot bar line velocity in real time. Using electronic cam (E-CAM) profiles, the shear accelerates, matches line speed within 0.05% error, executes the cut, and returns to home position smoothly.
Technical Architecture & Subsystems
Engineered fieldbus integration, high-speed loop cycles, and localized safety interlocks.
Dedicated multi-axis motion controller executing position loops at 0.888ms refresh rates.
37kW low-inertia AC servo motor with regenerative braking resistor bank for rapid deceleration.
Rugged water-cooled pinch roll encoder measuring continuous linear bar displacement without slippage.
Hardware & Modules Deployed
- Mitsubishi MR-J4 Series Servo Drive System
- Digital Dream Motion Control & CNC Architecture
- High-Resolution Industrial Rotary Optical Encoders
- Yaskawa A1000 75kW Roughing Stand Drive
- IP65 Sealed Field Terminal Enclosures
Facing Similar Machine Downtime or Inaccuracy?
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