G3/G4
PCB-Based REELEX Controls
The Future of REELEX Controls is Here.
The REELEX G3 Control System is an entirely new control system which pairs a proprietary custom-designed PCB (Printed Circuit Board) with a high-definition touchscreen HMI interface.
G3 Overview
Replacing nearly all of the circuitry in the legacy “G1” REELEX machines, the G3 Winding Module circuit board combines encoder monitoring, processing, calculations, I/O and interfacing onto a single integrated unit. These components interact with existing I/O boards to control machine functions.
Interfacing with the Winding Module is a high-definition Red Lion Graphite 12-inch HMI running proprietary REELEX software. This software brings REELEX equipment well into the 21st century, with real-time troubleshooting, multi-language support, recipe functions, networking functionality and more.
Legacy REELEX machines can be upgraded in the field with G3 controls, effectively bringing older equipment to modern standards.
Software Features
Increased control over coil formation. G2 and G3 controls are loaded with the latest REELEX coiling software. Take advantage of increased precision over coil density, and incorporate the revised hole taper programming to make payout holes straight, while eliminating “lumps” in the coil.
Advanced Tension Control. When paired with a digital regulator, the software allows each product can have their ideal tension control map, helping to mitigate the effects of physical pressure placed on the cable at the crossover point. This feature has shown to improve electrical properties of twisted-pair cables.
On-Screen REELEX Calculator. The calculator allows process engineers to select different machine settings for different products and see the impact on coil and package sizes. When finished, a single button sets up the machine to wind the calculated product.
Product Recipe Storage and Callup. Product settings can be saved with a ID or part number as well as a detailed description. Switching products is as simple as pressing which part number is being packaged.
Extensive Equipment Setup Options. Spark testing, sequential printing, footage scaling, online and offline operation are all supported and configurable via HMI.
Control over Machine Behavior. Easily change how the machine behaves when it encounters a print signal, spark fault and more. Easily set up the machine for online, offline, sequential printing or alternate modes of operation.
Security Username and Passwords. Users can be defined and prevented from changing certain settings or accessing certain parameters.
Restrict Specific Screens. Configure access for maintenance, settings and product select screens separately.
Operator Login. Turn on the operator login screen to record who is using the machine and when.
Safety First. With G2 and G3 controls, the status of nearly all machine functions are displayed on screen – no need to stop or get into the machine in order to understand valve or switch status.
Maintenance Readouts. Maintenance screens display valve, switch, encoder and sensor function in real-time to help in diagnosing issues and without opening up control cabinets.
On-screen Manuals. A comprehensive manual is available via the help screens, including procedures, preventative maintenance schedules and more.
Ethernet Networking. G2 and G3 allow REELEX machines to send and receive data to a central location or interface with other equipment in the line. Running a product can be as easy as scanning a barcode on a work order. Communicating with other devices is simple and customizable, and web access is supported if required.
Built-In Analytics. See number of coils produced in an hour or an 8-hour shift, see the lengths of the last 100 coils produced or download the machine logs via USB or network.
Raw Data Output. Access the raw modbus data for use in IoT industrial monitoring services such as Wonderware®
Multi-Language Support. The HMI can be configured to display in multiple languages including spanish, portugese, korean, chinese, japanese, turkish, polish and more.
Intuitive User Experience. The HMI is divided into Home, Products, Settings and Maintenance screens, each with content-specific help files. Navigating the HMI is simple and intuitive, with information right at your fingertips.
Comprehensive On-Screen Help. Screen-specific help screens tell you what you need to know based on what you’re doing. Detailed troubleshooting manuals are on-screen as well including best practices, problem solving and more.
G2/G3 HMI Overview Video
G3 Upgrade for Legacy REELEX Machines
Legacy G1 D-750 and D-510 machines can be field-upgraded with G3 controls via an upgrade kit.
This kit replaces the fundamental control system on G1 machines with G3 components and mounts to the existing control cabinet. This upgrade is performed by REELEX technicians and takes less than three days.
G3 Controls Upgrade
The REELEX G3 Control System is an entirely new control system which pairs a proprietary custom-designed PCB (Printed Circuit Board) with a high-definition touchscreen HMI interface.
Replacing nearly all of the circuitry in the legacy “G1” REELEX machines, the G3 Winding Module circuit board combines encoder monitoring, processing, calculations, I/O and interfacing onto a single integrated unit. These components interact with existing I/O boards to control machine functions.
Interfacing with the Winding Module is a high-definition Red Lion Graphite 12-inch HMI running proprietary REELEX software. This software brings legacy REELEX equipment into the 21st century, with real-time troubleshooting, multi-language support, recipe functions, networking functionality and more.
Legacy REELEX machines can be upgraded in the field with G3 controls, effectively bringing older equipment to modern standards.
The G3 Upgrade Includes:
Includes:
- 12-inch High-Definition Touchscreen
- I/O Module for HMI
- Prewired Control Buttons and Labels
Includes:
- Cables and connectors for integrating with existing I/O.
- WM/01-P Winding Module Circuit board and housing.
- PB24WM board for interfacing I/O with the Winding Module.
- Relays and power supply.
Includes:
- Digital air regulator assembly and feed
Functions:
- Replaces air regulator on dancer or UDA
- Enables tension to be controlled via HMI
- Includes Digital Air Regulator and Associated Hardware
Function:
- Increases resolution of existing counter from 4 pulses to 10 pulses per revolution for increased accuracy and response.
Includes:
- Up to three days of labor is included in the price of the upgrade.
- Travel expenses are all-inclusive fixed destination charges per man, per day.
- Training and general machine tune-up are provided.
Function:
- Beginning in 2021, it is a priority of REELEX to ensure all equipment is operated safely. As a result, all new models and upgrades will include physical safety guarding as standard.