Great Controls Engineering Brings Custom Machines to Life

When a manufacturer discusses a project with a custom machine builder like Gemini Industrial, they often know what they need the machine to accomplish. But they may not realize how much engineering goes into making that machine work reliably in their operations.

Controls engineering is an important part of that success. Mechanical design determines how a machine is built and how its parts move. Controls engineering makes those movements happen in the right sequence and in a way operators can easily manage.

How Controls Engineering Coordinates the Machine

In a well-designed custom machine, controls are often working in the background. But to get the results you need, those controls have to coordinate movement, timing, logic, safety checks, and operator inputs. Controls engineering allows all aspects of the machine to work together so the machine can function safely. 

The Art of Operator-Friendly Controls

Operator interface design is one important piece of controls engineering. Even when a custom machine is performing a complex task, the operator should not have to make complicated adjustments throughout the process.

Operators should have the options they need to manage the machine, but not so many choices that they’re overwhelmed. A well-designed interface reduces the risk of error but still lets operators control the process properly.

Controls in Action: Rubber Extrusion Winding

One of our recent projects shows how controls engineering can make a complex process easier to manage. We designed and built a rubber extrusion winder machine that takes one or more strips of rubber from an extrusion line and winds them onto as many as six spools at the same time.

One challenge, though, is matching the feed rate of the customer’s process. That rate may be mostly consistent, but it can change when material is replaced or the line pauses.

Strong controls engineering makes that operation look simple. The machine coordinates multiple winding points and gives operators a way to manage the process. It enables an efficient winding operation that is easier for customers to run during production.

Integrating Mechanical Design and Controls for Better Results

On some custom machine projects, controls engineering is treated as a separate step that happens after the mechanical design is mostly complete. But at Gemini Industrial, we take a different and more integrated approach.

Our controls programmers have a strong understanding of the mechanical side of the machine, and our whole engineering team works closely together throughout the project. Mechanical, electrical, and controls engineering are all part of one continuous design process.

Because of this collaboration, important details and design intent don’t get lost in handoffs between separate departments. Customers will receive a custom machine that is mechanically sound and intelligently controlled, ready to increase efficiency and safety on their shop floor.

Controls Engineering Can Improve Your Processes

If you have a bottleneck in your operations, the right custom machine can create significant manufacturing process improvements. Gemini Industrial can help you understand your challenge and develop a practical solution.

If you have an idea for a custom machine project, contact us today!