Retrofit of Round Bar Grinding Lines

Complete software and hardware retrofit of cylindrical grinding lines — grinding wheel and counter-roller — for the continuous processing of round bars. The project replaces obsolete control systems with a modern solution based on Schneider Electric hardware and CODESYS/SoMachine software, preserving existing mechanics and significantly reducing costs compared to full machine replacement.

The control system manages all working axes in an integrated manner: speed and current of both motors, advancement increment management with resolution to the hundredth of a millimetre, bar stopping system with configurable timings, and raise/lower commands for loading. Real-time monitoring includes lubrication flow and oil level, with dedicated alarm management accessible from the HMI.

The retrofit was implemented in two variants: with and without the workpiece centre-tracking system, to adapt to different line configurations. Communication is via Modbus and CANopen, ensuring full compatibility with the Schneider Lexium 32 drives and ATV inverters installed.