Figure 1: Buncher Machine Overview
🎯 Project Objective
The project was implemented to upgrade the outdated control system of the bunching line, aiming to improve system stability, productivity, and cable quality. At the same time, it helps minimize downtime and maintenance costs for one of Vietnam’s largest electric cable manufacturers.
⚙️ Scope & Technical Solution
Old System: Outdated analog controller, difficult to tune speed and twisting force, and no longer has replaceable parts.
New Solution by Kỹ Thuật Việt:
- Replaced the entire control system with Parker DC590P and AC30 drives.
- Applied Wireless PLC Communication between two electrical cabinets – the rotor (buncher) cabinet and the Capstan cabinet, eliminating the traditional Slip Ring technology.
- Integrated a custom-designed HMI by Kỹ Thuật Việt with an intuitive interface for easy monitoring and parameter setup.
- Updated the Bunching Synchronization algorithm between the twisting, capstan, and take-up motors.
- All axes are equipped with encoder feedback, achieving ±0.1% speed accuracy and perfect synchronization.
- The system supports production data logging, error warnings, and remote support via LAN network.
Figure 2: Kỹ Thuật Việt technicians installing the control cabinet
💡 Comparison: Wireless PLC vs Slip Ring
In traditional buncher machines, control signals between the rotating and stationary parts are transmitted through a Slip Ring system. However, slip rings have several drawbacks:
- Signal interference and data loss at high rotation speeds.
- Mechanical wear requiring frequent maintenance.
- Short lifespan and limited reliability.
The Wireless PLC Communication solution by Kỹ Thuật Việt provides:
- Stable, noise-free data transmission even at high speeds.
- No mechanical maintenance – completely eliminates slip ring wear.
- Real-time synchronization with high reliability and safety.
- Flexible expansion capability for future upgrades.
Figure 3: Old control cabinet inside the buncher machine
Figure 4: New control cabinets for twisting, laying and take-up sections
💻 System Interface & Architecture
The HMI system was custom-designed by Kỹ Thuật Việt – displaying all key parameters such as motor data, tension, torque, speed, faults, and real-time alarms.
Figure 5: HMI interface
All motor sections are controlled by Parker DC590P and AC30 drives, monitored via LAN network.
Figure 6: Old Capstan control cabinet
Figure 7: New Capstan control cabinet
📈 Project Results
- Production speed increased by 25%.
- Improved twisting stability and cable quality.
- Reduced maintenance time and troubleshooting.
- Fully synchronized system – easy to expand in the future.
🧠 Added Value
The project showcases the in-depth Motion Control expertise and extensive practical experience of Kỹ Thuật Việt – Parker Drives Vietnam in the cable manufacturing industry.
We are proud to deliver optimized, stable, and long-term solutions for cable factories nationwide.
🎥 Project Video – Wireless PLC Communication System for Buncher Machine
Watch how Kỹ Thuật Việt implemented the wireless communication solution between two control cabinets – the rotor (buncher) and the capstan, ensuring smooth, safe, and perfectly synchronized operation.
Video: Buncher Machine Upgrade Project – Wireless PLC Communication Solution by Kỹ Thuật Việt
📞 Contact for Consultation
If you are operating bunching, stranding, drawing, or cable coiling lines and need to upgrade your control system – contact us today for the most suitable solution:
- 🏢 Ky Thuat Viet Co., Ltd – Parker Drives Vietnam
- 📧 Email: info@kythuatviet.com
- 📞 Hotline: +84 908353714
- 🌐 Website: www.kythuatviet.com
