▦ PORTFOLIO — SIMULATION
Pipe/Profile Bundling Line Post-Cut Grouping & Bundling
Line simulation where post-cut pipes and profiles are counted, grouped and bundled with a servo strapping unit. Counting, stacking logic and belt synchronization.
Bundling Counting Conveyor CODESYS Lenze i550 Lenze c430
BUNDLE / COUNT v1.0 | Bundling Line Controller
● RUNNING
▸ INPUT
SPD60m/min
RATE40/min
▸ COUNTING
COUNT0/ 6
▸ STACKING
LAYER0/ 3
IN LYR0
▸ STATUS
STATECOLLECT
▸ OUTPUT
BUNDLES0
TOTAL0
▸ AXES
INFEED OK
OUTFEED OK
STRAP OK
SPEED 1.0 ×
BUNDLE pcs
SFC: Bundling · Counting · Sync What Does It Do?
- ▸ Counts post-cut pipes with sensor, forms bundle when target count is reached
- ▸ Buffer zone allows cutting and bundling to proceed simultaneously without line stops
- ▸ Servo strapping unit automatically wraps and tightens the bundle
- ▸ Bundle size is programmable from the operator panel
How Does It Work?
- ▸ SFC (Sequential Function Chart) drives ACCUM → STRAPPING → EJECTING cycle
- ▸ 100% accuracy with sensor counting, no mechanical counter errors
- ▸ Lenze i550 servo module offers an economical solution.
- ▸ Belt speed synchronization: input and output belts run in sync
Industrial Use Cases
- ⚙ Steel & aluminum pipe mills
- ⚙ Profile & section rolling lines
- ⚙ Wire drawing & coil lines
- ⚙ HDPE / PP plastic pipe extrusion
- ⚙ Rebar & construction steel lines
// Mechanical Counter vs. Encoder Counting
| Criterion | ❌ Mechanical / Manual | ✅ Encoder + Servo |
|---|---|---|
| Counting accuracy | 95% (mechanical) | 100% (encoder) |
| Bundle size | Fixed | Programmable |
| Line stoppage | Frequent | Zero (with buffer) |
| Belt sync | Manual | Automatic |
| Strapping speed | Slow (pneumatic) | Fast (servo) |
// Typical Application Parameters
| Parameter | Value | Unit / Note |
|---|---|---|
| Max pipe diameter | 160 | mm |
| Bundle count | 3–24 | pcs |
| Line speed | up to 80 | m/min |
| Strapping time | <2 | sec |
| Software | CODESYS v3.5 | SFC+LD |
| Servo | Lenze i550 | AC Motor with Servo Control |
| PLC Task Cycle | 1 | ms |
// Cycle Phases
IDLE
System ready, line running, waiting for pipe input
COLLECTING
Pipes conveyed from line belt, counted by encoder into collection zone
ACCUMULATING
Target count reached; rows stacked on top of each other to form bundle
STRAPPING
Servo strapping unit wraps bundle with tension-controlled tightening
EJECTING
Completed bundle transferred to output belt via pusher
RESET
Pipe and bundle counters reset, system ready for new cycle