A IMPLEMENTATION OF A SAFETY SYSTEM FOR A REBAR UNCOILING MACHINE WITH INTEGRATION OF AN AUTOMATED PRODUCTION COUNTING SYSTEM

Abstract

This study presents the implementation of an automated safety and production counting system in a rebar decoiling machine through the retrofit technique. The research aims to modernize the equipment, enhance operational safety, and optimize production control. The proposed solution incorporates safety devices, safety sensors, a Programmable Logic Controller (PLC), a Human-Machine Interface (HMI), and an inductive sensor to automate the counting of cut rebars and monitor the production process. The methodology consists of applied experimental research involving the development of control logic, component installation, and system validation through operational testing. The operator sets the desired number of cuts through the HMI, while the PLC manages motor actuation, production counting, and safety interlocks. The results demonstrate that the system correctly executes the control logic, achieving 100% accuracy in rebar counting during the conducted tests. The safety devices exhibited response times below 500 ms, ensuring the safe shutdown of the equipment under hazardous conditions. The tests also confirmed the proper operation of the safety interlocks under simulated fault scenarios. It is concluded that the retrofit process contributes to compliance with safety requirements, improves production control, and reduces the likelihood of operational errors, proving to be a technically and economically viable alternative for the modernization of industrial machinery.