Because of their superior functionality, comprehensive performance range and application flexibility, the Siemens Simovert MASTERDRIVES in CUVC, CUMC, Compact form and other variants has been a very successful drive system for single motor and multi-motor applications. The established common DC bus system enabled it to be used on demanding production machine processes across a wide range of industry sectors.
All good things must come to an end, but that doesn’t mean the end of the line for your production machine.
Optima’s innovative approach to upgrades significantly reduces the installation time and minimises risk to your site. All of our systems are thoroughly tested before they are shipped to site, completely eliminating any “out of box” failures.
Some of the benefits you will realise are:
Extended life span of your machine and increased availability due to continued spare parts supply with full support by Siemens
Improved productivity through lower energy costs and faster production cycles, through:
Simple operation monitoring using operator panel
User-friendly diagnostics with the STARTER tool
Additional interface options via PROFINET or PROFIBUS
Future-proofed due to access to the new world of TIA Portal
Optima’s approach for upgrades is to:
1.Analysis of your current machine configuration and potential further customer request
Recommendation on the best replacement scenario
Installation, configuration and commissioning of new components and creation of circuit diagram and documentation
Acceptance test and machine handover.
If requested, we can also provide training for all your relevant engineers and instruction of the operating personnel
We’ve been upgrading complex drive systems for over 20 years
We are one of only 7 authorised Siemens Drives and Motion partners in the UK
We provide a complete solution provided by one retrofit supplier including mechanical installation of motors and/or supply of adaptor plates and flanges to suit
When faced with the unreliability and ageing Crabtree motor starter sets, a leading manufacturer of waterproofing products turned to Optima for assistance. The existing pump control system was direct on-line and required pump changeovers to be initiated manually.
Old Pump Control Starter Panels
The solution was to replace the existing starter panels with a single panel housing 18.5kW and 30kW variable speed drives with a S7-1200 PLC controlling pump changeover from a 4 inch Basic HMI. This display shows providing pump status, hour run and pump selection buttons and also allows the system to run in fully Automatic or Manual modes.
New Pump Control Panel In-Situ
The installation task had to be completed during a weekend shutdown, requiring careful coordination between production and our engineering team to schedule the works.
Inside The New Control Cabinet
The system was powered up ready to run in full production before Monday’s switch-on.
This is our first batch of UL-Rated control panels completed and ready for storage prior to shipping to the United States. This is part of a fully integrated Rockwell Automation control system featuring ControlLogix PLC’s with Guard Logix Safety and PowerFlex Drives.
When a major paper producer was faced with increasingly temperamental performance from the existing hydraulic drive control system on their Valmet KL Winder, they turned to Optima for assistance. The system suffered from uncontrolled starting from cold until the hydraulics had reached normal temperature. However, even at normal operating temperature, there were still issues with tension control being unpredictable.
Optima were asked to suggest possible upgrade solutions for the winder. Our solution was to use a Siemens Sinamics drive system, controlled from our own custom-written winder blocks. Optima’s winder blocks are PLC-based and provide all the functionality required of any winding application.
The new drive system was specifically designed to suit the exact material tensions, roll diameters and operating speeds of the winder to ensure both performance and cost needs were met. The actual products run on winders sometimes differ from the manufacturers own design.
A complete new control suite was built to house the new PLC and drive hardware. Installation was managed by Optima.
Final Commissioning was carried out by our own engineers specialising in web transport systems.
Tuning of the fully-compensated system was carried out over a series of product trials on different grades of paper. The drive control system is complex, not just for accurate tension control but also to drive either end of the paper unwind with separate AC geared motors – not an easy task to achieve. Optima’s control algorithms ensure that control of the unwind reel is shared equally between each drive whilst also preventing ‘slippage’ of the driving mandrel within the unwind core.
Optima will be pleased to provide a no-obligation site visit to discuss how we might improve the performance of your existing winder or for a completely new upgrade.
Please telephone: Andy Coverdale or Mark Lane on 01254 272829 to discuss your requirements in more detail.
Led by Professor Juergen Maier, CEO of Siemens, Made Smarter is the Government’s white paper that aims to set an agenda that can drive productivity and growth in UK industry.
Highlights of the report include introductions to industrial digitalisation and the benefits that this can offer across the manufacturing sector. It also presents the key themes that are preventing the UK becoming a leader in Industrial Digital Technologies (IDT) and provides some suggestions as to how industry might accelerate the implementation of IDT.
The full document can be downloaded from the following link:
Pepperl+Fuchs are taking to the road to showcase their latest innovations. Their Team will be at Optima and we’d like to invite you to join us!
Step inside and meet Optima’s and Pepperl+Fuchs highly experienced team of engineers who are on board and ready to discuss your automation needs and demonstrate how our sensing technologies can improve processes. From our latest innovations, SmartBridge, IO-Link, Smart Runner to our more tried and tested solutions.
In this upgrade, carried out during a planned shutdown, an Automax controller and obsolete DC drives were removed and replaced by new AC Powerflex 753 drives and AC vector motors. The SLC500 rack was replaced by a new Control Logix rack and remote IO on Ethernet. The now redundant PanelMax HMI was replaced by a new InTouch system from Wonderware.
The full scope of work, carried out by our own engineers in-house included:
Hardware calculations/rating for drives
Customer project specifications for upgrade
Project design specification
Full Circuit diagrams for the upgraded equipment
Test documents to validate the new equipment operation
Software specifications and sequence diagrams
Details of a typical metalliser drive control system are shown below. Optima know the metalliser drives process intricately. We have upgraded over 10 metalliser drive systems from various manufacturers and can offer a comprehensive upgrade to bring control of your machine drive system up to the standards of a new metalliser.
Optima will be pleased to provide a no obligation site visit to discuss how we implemented this upgrade and how we can help upgrade your machine to new supportable equipment.
Please telephone: Andy Coverdale,Mark Lane, Michael Hill on 01254 272829 to discuss your requirements in more detail. Alternatively e-mail us at E-Mail Sales.
Optima were approached by an internationally renowned packaging manufacturer, particularly specialised in cartons, labels and leaflets. The company’s manufacturing facilities across the globe must deliver maximum efficiency and reliability to enable excellent customer service and innovative packaging designs.
Their Scotland-based plant was faced with obsolescence and unreliability of a Sirpak 200 tube forming and cut to length machine. The linear tube-forming line on site is used for the production of all-shape composite cans. It allows the manufacturer to produce odd-shape packaging for premium brands such as Chivas Regal and Glenfiddich. Customers in this sector demand high-quality materials and unique packaging designs. If their supplier is unable to produce these up to standard and on time, it would be losing significant amounts of revenue. This is where Optima got involved to provide a stand-alone registration system to replace the existing cut-to-length equipment.
The new system that Optima developed incorporated a fully integrated Siemens platform with Simotion Drive equipment, Simatic PLC and a Siemens Synchronous Motor gearbox combination.
New features for the machine – a Sirpak 200 – included a recipe interface for the different packaging tube lengths produced on the machine. To minimise downtime at change-over from the old equipment to new, Optima installed a new panel, encoder and PEC next to the existing units without interfering with the existing control system. Because of this, the project commissioning was completed in 5 days without problems or delays.
Of greatest benefit to the customer is the reduction in waste that was achieved following the upgrade. Michael Hill, Managing Director at Optima, explained the future benefits further: “The current system was sheet-fed, which means there is unprinted material (3’’) between each repeat length. Following detailed consultation with the customer, Optima’s control system facilitated the use of printed rolls instead of sheets, thus eliminating the requirement for unprinted sections. With 3″ saved on every 40″ of material, the new system would facilitate a 7.5% reduction in product waste. As the company produces thousands of metres of carton per week (approximately 40 metres/minute for 10 hours per day, 5 days per week equating to 120,000 metres) the savings equate to 9km of less waste every week.”
Please telephone: Andy Coverdale, Mark Lane, or Michael Hill on 01254 272829 to discuss your requirements in more detail.
In this project, Optima provided a complete new control system for a Metal Decorating Press. In order to print the colours correctly aligned, all axes must be fully synchronised. Optima chose to use Sinamics S120 Drives and the D425 motion controller to achieve the required accuracy.
The control system was a completely integrated package from Siemens with use of remote IO stations to minimise machine wiring time.
This video was taken during final commissioning of the machine.
The project was managed from the initial site survey, through specification, design and finally commissioning on-site by Optima.
Initial advice was offered to the customer to cover aspects such as
Operational and process risk assessment
Fixed guarding integrity and guarding access points
Hazardous areas that require EEx rated equipment
This allowed to to design the system to accommodate machinery safety and environmental operating conditions in addition to the major drive control aspects.
The machine software was custom-developed for the application to encompass:
Main machine PLC sequences
Operator Visualisation (HMI)
Motion Control Equipment functionality
Safety Controller Programming/Configuration
Main Panel with Sinamics Drives on test before shipping
Main Operator Desk
All built equipment from Optima was tested for both build quality and correct functionality before the control enclosures were boxed and braced ready for shipping to site via sea freight.
Commissioning of the supplied control equipment and software was completed with the assistance of the end users engineering and operational personnel. This is important as it allows a natural ‘hand-over’ of equipment to the end user so they become comfortable with owning the new control system.
During this phase machine process functionality and machine operational safety was tested using the following documents supplied as part of the project such as:
Optima project design specification
Commissioning software test plan
Software specifications and sequence diagrams
Please feel free to speak to us and find out how we can help to upgrade your printing machines to the latest state-of-the-art automation hardware and give you total ownership of the eventual control system supplied.