Cam Controller

What is a cam controller?

An electronic cam controller is a control unit used in automation technology to switch electrical signals depending on the position of an axis (usually a rotating shaft). Cam controllers control depending on the machine position or are time-controlled. The function is comparable to the cams of a disc, where the switch-on and switch-off points are determined for each output according to the sections of the circle. In the past, this was solved purely mechanically (for example, with the help of our KWG cam switchgear) using a camshaft with small "bumps" (cams) that activated physical switches when rotating. The electronic version replaces these mechanical parts with digital logic and sensors. They are used wherever fast and accurate control is required in close correlation with the machine position. The machine's position is detected by an absolute rotary encoder, which transmits an absolute angle or distance measurement to the cam switch in accordance with the machine position.

What are the characteristics of cam controller?

• Angle-dependent switching: The signal output is precise based on the current position or angle of a rotating shaft.
• Real-time processing: Unlike a PLC, these systems operate with virtually no cycle time delay, enabling extremely fast switching operations.
• Wear-free digital technology: By eliminating mechanical cams and contacts, the system remains permanently maintenance-free and reliable.
• Intelligent dead time compensation: The device automatically compensates for actuator inertia by bringing forward the switching point at higher speeds.
• Precise position detection: The controller uses absolute value encoders, which means that the exact machine position is immediately known again even after a power failure.
• Dynamic optimization: Switching points and parameters can be adjusted during operation without stopping the machine.
• High program density: Several different switching profiles can be stored in the device and quickly retrieved when changing formats.
• Simple parameterization: Configuration is user-friendly and can be done either directly via a front-panel display or via PC software.

What are the areas of application for cam controller?

• Packaging machines: They control the precise timing of adhesive nozzles, welding tongs, or cutting devices at high cycle rates.
• Printing machines: Here, they ensure the exact synchronization of inking units, cutting registers, and perforation tools.
• Filling systems: Cam controllers coordinate the precise opening and closing of valves as the containers pass through.
• Labeling machines: They ensure that labels are always applied in exactly the same position, regardless of the line speed.
• Presses and punching machines: The devices control the material feed and the ejection of parts in perfect coordination with the press stroke.
• Woodworking: In continuous machines, they control the precise timing of milling heads or gluing units at the edge of the workpiece.
• Automated assembly machines: They synchronize complex pick-and-place movements and handling steps within short cycle times.

A significant advantage of the devices EPR, EPC is the possibility of optimising switching points in operating machines and compensating delay times of connected actuators, depending upon the speed (downtime compensation).

Other important advantages of all variants are the significantly high speeds as compared to the PLC, the exact switching points, multiple programmes in one device, simple programme designing and modification as well as accurate downtime compensation to precisely 1 ms.

Programming is done either via the keyboard and display integrated at the front or with the help of a connected PC.