FATEK Automation Corporation

The development and application of the roller-type round tube straightening machine represent a critical initiative in response to the strategic transformation of China's high-end manufacturing sector from "scale expansion" to "quality enhancement." Currently, in strategic emerging industries such as aerospace, new energy vehicles, and precision instruments, there are nearly stringent requirements for the geometric accuracy of metal round tubes, which serve as core structural components and functional transmission parts. Straightness deviations and ovality errors in traditional tubes, caused by rolling residual stress, machining deformation, and uneven cooling, have become bottleneck issues restricting the performance, reliability, and service life of high-end products. This critical "bottleneck" process shortcoming not only leads to low production efficiency and difficult breakthroughs in yield rates for downstream industries but also forces reliance on imported high-precision tubes in some high-end sectors. The core mission of this project is to overcome this underlying process problem that constrains industrial upgrading. By innovatively optimizing the layout of the straightening roller system and the motion control algorithm, precise and efficient control of the micro plastic deformation of the tube is achieved, thereby enabling the stable production of ultra-high-precision tubes that meet the requirements of extreme working conditions. This initiative aims to bridge the "last mile" from basic materials to high-end equipment, strengthening China's self-sufficiency and global market competitiveness in the field of high-performance component manufacturing, and injecting core driving force for quality and efficiency improvement across the entire industrial system.

► System Stability and Anti-interference Capability
The system design prioritizes reliability. The core controller, FATEK M-series PLC, features industry-leading anti-interference capabilities, effectively resisting complex electromagnetic radiation and surge impacts in industrial environments. It ensures distortion-free and lossless transmission of control signals and commands, minimizing system misoperation rates. Additionally, this PLC series supports critical hardware redundancy design, enabling seamless switching of control authority in case of single-point failures. This maximizes production continuity, meeting the requirements of uninterrupted continuous operation scenarios.

► EtherCAT High-speed Real-time Control
The system adopts advanced EtherCAT open fieldbus technology to build a high-performance real-time control network. Through deep integration of FATEK M-series PLC and SC3 series bus servo drives, this architecture easily achieves high-precision, multi-axis synchronous control of up to 16 servo axes. Its microsecond-level or even nanosecond-level clock synchronization mechanism ensures highly consistent actions of all straightening roller groups during high-speed operation, laying a solid foundation for uniform and precise straightening processes. Furthermore, the bus system natively supports advanced motion control functions such as electronic cam, virtual spindle, and phase synchronization, providing a powerful technical platform for implementing more complex and flexible straightening curves and processes.

► Full Servo Drive System
All motion axes of the equipment, including the pressure adjustment of each straightening roller group, feeding and discharging conveying, etc., adopt FATEK SC3 series high-performance bus servo drive systems. This system features fast response, high positioning accuracy, and strong overload capacity, enabling precise execution of motion commands from the PLC. By directly setting torque and position limits through the bus, precise control of plastic deformation during pipe straightening is achieved. This not only significantly improves product straightness and roundness consistency but also effectively avoids material damage or yield reduction caused by over-straightening or under-straightening.

► Summary of Solution Advantages
This technical solution integrates stability, high-speed synchronization, and precise control. Its full-bus architecture simplifies wiring, reduces costs and failure rates; strong anti-interference and redundancy capabilities ensure long-term stable operation of the equipment; and the combination of EtherCAT and full servo system directly elevates equipment performance to a new level, providing users with core competitive advantages in terms of straightening accuracy, production efficiency, and flexible production capabilities.