Roll Rewinder  Electrical Control & R&D Development

The Roll Rewinder is one of the key subsystems in our Track & Trace packaging line — responsible for collecting printed web material while maintaining precise tension, speed, and alignment control
In this project, I led the electrical and automation design, developed the servo motion logic, and coordinated with the mechanical and software teams to bring a smooth and synchronized rewinding system to production

My Role

As an automation engineer and R&D lead, I designed and implemented

• Electrical panel layout and wiring, including servo drives, safety relays, and motion sensors

• PLC program for torque and speed control with encoder feedback

• HMI interface for operator adjustment of speed, diameter, and tension

• Synchronization logic with the upstream printer and vision modules

• Testing & commissioning, including speed calibration and web tension optimization

I also worked closely with the mechanical design team to tune the motion profile — ensuring soft start/stop curves, stable rewinding even at variable diameters, and smooth material handling without slippage

Technical Highlights

• Servo control with closed-loop feedback for real-time torque compensation

• Dynamic diameter calculation for automatic speed regulation

• Integrated brake control and safety stop interlock

• Auto-tension mode with adaptive PID tuning

• Data communication between PLC, HMI, and printer via Modbus RTU/TCP

Future Improvements

The next generation of this unit will include

• Dual-motor torque balancing for higher tension accuracy

• Auto-core positioning and diameter sensing

• HMI-assisted diagnostics with trend graphs and alarm history

• Integration with central production reporting system

My Vision

My focus is to make the rewinder a modular, reusable automation unit — easily adaptable for various roll widths and line speeds, while maintaining safety, precision, and operator-friendly usability