Industrial Machine Design & Modernisation

About this area

Industrial machine design and modernisation

We design and deliver comprehensive industrial solutions: machines, production lines and process systems. We also modernise existing machinery, adapting it to new production technologies without the need for complete replacement.

RCE Automatyka carries out projects of this type in the automotive, rubber and food industries, where minimising downtime and maximising machine potential are critical. Modernisations cover mechanical and electrical scopes as well as PLC control systems and the integration of new production functionalities.

Modernisation of a rubber winding and drum-feeding machine

⚠ The Challenge

A project carried out for an international corporation in the tyre industry. The machine feeding rubber onto a drum had been designed for a single process only and could not handle the client's new technological requirements.

• Limited control of the rubber winding and drum-feeding process, preventing the manufacture of more technologically advanced products
• Low machine flexibility — no ability to easily adapt to different production parameters
• Requirement to complete the modernisation while maintaining production continuity

✓ The Solution

We carried out a comprehensive modernisation of the machine responsible for winding rubber and feeding it precisely onto a drum, without interrupting the client's production continuity.

1.
Mechanical system expansion: New components responsible for material guidance, stabilisation and application of material onto the drum in accordance with process specifications
2.
Modern drives and control: Precise motion synchronisation and accurate material tension control
3.
PLC system modernisation: Implementation of new winding process control algorithms
4.
Support for multiple process variants: Adaptation of the machine to different material and winding parameters
5.
Production line integration: Full integration of new functionalities with the existing line and other machines in the plant
6.
Documentation and support: Complete technical documentation and support during commissioning and process optimisation

★ Client Benefits

The modernisation enabled the end client to manufacture more technologically advanced products while ensuring full stability and predictability of the winding process.

Benefits achieved:

Ability to manufacture more technologically advanced products
Process stability through full control of material tension, speed and positioning
Production flexibility — operation with different material variants and settings
Reliability — new drive systems and control reduce the risk of failure
Extended machine service life — modernisation instead of costly equipment replacement

Modernisation without downtime

We tailor every solution and integrate hardware from any manufacturer

Industrial rubber winding machine after modernisation

PLC control system of the production machine

Production stoppages

100%

Process control