{"id":5968,"date":"2026-03-17T12:04:57","date_gmt":"2026-03-17T11:04:57","guid":{"rendered":"https:\/\/neotech.pl\/maszyny\/en\/?page_id=5968"},"modified":"2026-03-17T13:23:58","modified_gmt":"2026-03-17T12:23:58","slug":"detzo-winders-modernization","status":"publish","type":"page","link":"https:\/\/neotech.pl\/maszyny\/en\/products\/machine-modernization\/detzo-winders-modernization\/","title":{"rendered":"DETZO Winders Modernization"},"content":{"rendered":"\t\t
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DETZO Winders Modernization \u2013 advanced reconstruction of control and drive systems<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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DETZO winders, especially in their four-spindle configuration, are technologically advanced stations for the production of left- and right-handed layered coils. Despite their robust mechanical design, their control architecture, drive systems, and safety features often fail to meet modern requirements for precision, integration, and reliability.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Professional modernization of winders and other devices allows them to be transformed into fully functional, digitally controlled production systems \u2013 without the need to invest in new machines.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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\n \n\t\t\t\t\t\t\t\t\t\t<\/i> <\/div>\n <\/div>\n\n \n DETZO Winder Modernization - The Starting Point, or Technical Characteristics of the Machine<\/span>\n\n \n <\/a>\n <\/div>\n\n
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DETZO winders operate in an automatic cycle on multiple spindles (typically 4), implementing complex motion paths along the following axes:<\/span><\/p>

\u25cf X (left-right),<\/span><\/p>

\u25cf Y (forward-backward),<\/span><\/p>

\u25cf Z (up-down),<\/span><\/p>

\u25cf Q (spindle\/beam rotation).<\/span><\/p>

The mechanical system is based on belt drives for individual axes and spindles, which results in:<\/span><\/p>

\u25cf limited dynamic stiffness,<\/span><\/p>

\u25cf susceptibility to wear and decalibration,<\/span><\/p>

\u25cf necessitating periodic adjustments and replacement of transmission components.<\/span><\/p>

Additionally, the machine utilizes:<\/span><\/p>

\u25cf\u00a0 \u00a0pneumatic carcass clamping and spindle locking systems,<\/span><\/p>

\u25cf\u00a0 \u00a0mechanical spindle indexing every 30\u00b0,<\/span><\/p>

\u25cf\u00a0 \u00a0a distributed control system based on an industrial computer and I\/O modules.<\/span><\/p>

These areas constitute the main scope of potential modernization.<\/span><\/p> <\/div>\n\n <\/div>\n\n <\/div>\n\n \n

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\n \n\t\t\t\t\t\t\t\t\t\t<\/i> <\/div>\n <\/div>\n\n \n Modernization Results \u2013 Parameters and Performance<\/span>\n\n \n <\/a>\n <\/div>\n\n
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After modernization, the DETZO winder achieves parameters comparable to new machines:<\/span><\/p>

Precision:<\/span><\/p>

\u25cf Axis positioning accuracy of tenths of a millimeter,<\/span><\/p>

\u25cf Precise spindle angle control (below 1\u00b0).<\/span><\/p>

Efficiency:<\/span><\/p>

\u25cf Shorter cycle times,<\/span><\/p>

\u25cf Continuous operation with minimal downtime.<\/span><\/p>

Repeatability:<\/span><\/p>

\u25cf Full reproducibility of winding programs,<\/span><\/p>

\u25cf Elimination of the impact of mechanical wear on product quality.<\/span><\/p>

Diagnostics and Service:<\/span><\/p>

\u25cf Quick error identification,<\/span><\/p>

\u25cf Remote access and service support,<\/span><\/p>

\u25cf Monitoring of process parameters.<\/span><\/p> <\/div>\n\n <\/div>\n\n <\/div>\n\n \n

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\n \n\t\t\t\t\t\t\t\t\t\t<\/i> <\/div>\n <\/div>\n\n \n Modernization vs. Purchasing a New Machine \u2013 Technical and Economic Analysis<\/span>\n\n \n <\/a>\n <\/div>\n\n
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In the case of DETZO winders, it is particularly important that:<\/span><\/p>

\u25cf\u00a0 \u00a0the mechanical structure (frame, guides, handles) is durable,<\/span><\/p>

\u25cf\u00a0 \u00a0the main limitations result from outdated automation,<\/span><\/p>

\u25cf\u00a0 \u00a0retrofit allows for the preservation of existing infrastructure.<\/span><\/p>

Modernization enables:<\/span><\/p>

\u25cf\u00a0 \u00a0reduction of investment costs by up to 50\u201370%,<\/span><\/p>

\u25cf\u00a0 \u00a0shortened implementation time,<\/span><\/p>

\u25cf\u00a0 \u00a0customization of functionality precisely to the customer's process.<\/span><\/p> <\/div>\n\n <\/div>\n\n <\/div>\n\n \n

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\n \n\t\t\t\t\t\t\t\t\t\t<\/i> <\/div>\n <\/div>\n\n \n Why is winders modernization at NEOTECH worthwhile?<\/span>\n\n \n <\/a>\n <\/div>\n\n
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By choosing machine modernization at NEOTECH, customers receive not only a technical upgrade but also a comprehensive engineering approach based on years of experience in industrial automation and winding system construction.<\/span><\/p>

Each project is individually implemented \u2013 from a detailed technical audit, through drive and control system design, to implementation and optimization of the production process. This allows modernized machines to achieve parameters comparable to new equipment, while maintaining existing infrastructure and significantly lowering investment costs.<\/span><\/p>

NEOTECH also provides full after-sales support, software development, and the possibility of further system expansion in the future, making modernization a safe and scalable investment.<\/span><\/p> <\/div>\n\n <\/div>\n\n <\/div>\n\n <\/div>\n <\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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See how we modernize METEOR winders:<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Winder modernization - a full-scope system approach<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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\n \n\t\t\t\t\t\t\t\t\t\t<\/i> <\/div>\n <\/div>\n\n \n 1. Drive system reconstruction - Retrofit motion system<\/span>\n\n \n <\/a>\n <\/div>\n\n
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A key modernization step is the transition from classic belt drives and asynchronous motors to servo drive systems:<\/span><\/p>

\u25cf Implementation of servo motors for the X\/Y\/Z\/Q axes,<\/span><\/p>

\u25cf Use of absolute or incremental encoders,<\/span><\/p>

\u25cf Elimination of backlash through digital backlash compensation,<\/span><\/p>

\u25cf Synchronization of multi-axis movements (interpolation).<\/span><\/p>

Results:<\/span><\/p>

\u25cf Significant increase in positioning accuracy,<\/span><\/p>

\u25cf Ability to implement complex winding trajectories (e.g., variable pitches),<\/span><\/p>

\u25cf Process stabilization at high speeds.<\/span><\/p> <\/div>\n\n <\/div>\n\n <\/div>\n\n \n

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\n \n\t\t\t\t\t\t\t\t\t\t<\/i> <\/div>\n <\/div>\n\n \n 2. Spindle Drive Modernization<\/span>\n\n \n <\/a>\n <\/div>\n\n
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In the original configuration, the spindle drive is provided by toothed belts (e.g., 800 5M), which limits:<\/span><\/p>

\u25cf\u00a0 \u00a0dynamic speed changes,<\/span><\/p>

\u25cf\u00a0 \u00a0angular positioning accuracy,<\/span><\/p>

\u25cf\u00a0 \u00a0process repeatability.<\/span><\/p>

The modernization includes:<\/span><\/p>

\u25cf\u00a0 \u00a0use of independent servo drives for each spindle,<\/span><\/p>

\u25cf\u00a0 \u00a0implementation of electronic synchronization (electronic gearing),<\/span><\/p>

\u25cf\u00a0 \u00a0real-time torque and wire tension control.<\/span><\/p> <\/div>\n\n <\/div>\n\n <\/div>\n\n \n

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\n \n\t\t\t\t\t\t\t\t\t\t<\/i> <\/div>\n <\/div>\n\n \n 3. Digitalization of the control system<\/span>\n\n \n <\/a>\n <\/div>\n\n
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The original system, based on an industrial computer and dedicated software, can be replaced with:<\/span><\/p>

\u25cf\u00a0 \u00a0an industrial-grade PLC controller,<\/span><\/p>

\u25cf\u00a0 \u00a0an HMI system with process visualization,<\/span><\/p>

\u25cf\u00a0 \u00a0a distributed architecture (EtherCAT \/ Profinet),<\/span><\/p>

\u25cf\u00a0 \u00a0process parameterization via recipes.<\/span><\/p>

New capabilities:<\/span><\/p>

\u25cf\u00a0 \u00a0winding program management,<\/span><\/p>

\u25cf\u00a0 \u00a0online diagnostics (I\/O, axis positions, errors),<\/span><\/p>

\u25cf\u00a0 \u00a0integration with MES\/ERP systems.<\/span><\/p>

The initial solution included features such as:<\/span><\/p>

\u25cf\u00a0 \u00a0an I\/O diagnostic panel,<\/span><\/p>

\u25cf\u00a0 \u00a0motor position monitoring,<\/span><\/p>

\u25cf\u00a0 \u00a0user and service programs.<\/span><\/p>

In modernization, they are significantly expanded and standardized.<\/span><\/p> <\/div>\n\n <\/div>\n\n <\/div>\n\n \n

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\n \n\t\t\t\t\t\t\t\t\t\t<\/i> <\/div>\n <\/div>\n\n \n 4. Modernization of safety systems<\/span>\n\n \n <\/a>\n <\/div>\n\n
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DETZO winders are equipped with, among other things:<\/span><\/p>

\u25cf EMERGENCY STOP to cut off the power supply,<\/span><\/p>

\u25cf mechanical spindle locks,<\/span><\/p>

\u25cf work area guards.<\/span><\/p>

The modernization includes:<\/span><\/p>

\u25cf implementation of safety systems (PL d \/ SIL 2),<\/span><\/p>

\u25cf use of safety relays and safety PLC controllers,<\/span><\/p>

\u25cf door\/guard monitoring (interlock),<\/span><\/p>

\u25cf safe drive stopping (STO, SS1).<\/span><\/p> <\/div>\n\n <\/div>\n\n <\/div>\n\n \n

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An important element is the optimization of:<\/span><\/p>

\u25cf\u00a0 \u00a0spindle lock actuators,<\/span><\/p>

\u25cf\u00a0 \u00a0body clamping systems,<\/span><\/p>

\u25cf\u00a0 \u00a0working pressure control (typically 0.6\u20130.65 MPa).<\/span><\/p>

Possible improvements:<\/span><\/p>

\u25cf\u00a0 \u00a0position and pressure sensors,<\/span><\/p>

\u25cf\u00a0 \u00a0automatic clamping accuracy check,<\/span><\/p>

\u25cf\u00a0 \u00a0synchronization of pneumatics with the CNC cycle.<\/span><\/p> <\/div>\n\n <\/div>\n\n <\/div>\n\n <\/div>\n <\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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The modernization of DETZO winders is an advanced engineering process involving the full integration of new control, drive and safety systems with the existing machine mechanics.<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Thanks to the use of modern technologies \u2013 from servo drives, through PLC systems, to digital diagnostics \u2013 it is possible to achieve high precision, repeatability and reliability of the winding process.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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This solution is especially recommended for production plants that want to increase their competitiveness without having to replace their entire machinery.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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Are you interested in options of winders modernization? Contact us and find out how we can help you!<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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