Out with the old, in with the NEW…Optima uses ctrlxautomation to retrofit a mid 90s printing application with the latest of Bosch Rexroth solutions. Both ctrlX CORE & DRIVES were used and completed in record time due to Simulated testing. But… Just look at the reduced cabinet space!
See the full article on LinkedIN and more details below:
The innovative sinamics G220 variable frequency drive from Siemens not only helps reduce harmonics (Gary Wilcock) but is also a more sustainable drive choice. Let us explain.
The animation below shows the draft panel layouts for 8 drives using the G120 drives along with the required input and output reactors due to the long cable lengths involved for this installation.
It has helped Optima Control Solutions Ltd make this a more sustainable design.
Not only have we have reduced CO2 emissions in transit as the cabinet is lighter, we have also reduced the amount of minerals required to build by avoiding additional copper in the line chokes and steel in the chokes and cabinets.
The fusing for the other 8 drives has been moved to an adjacent cabinet where there are other drive sizes located. The control panel build is now underway.
A big thanks to Ben Poole, too for his timely demonstration of these excellent drives. Sustainability CleanTech
When our customer needed to upgrade their aging batch processing and bulk delivery systems on site, they turned to Optima Control Solutions.
Optima were tasked with migrating the legacy control system over to a modern integrated batch control solution with no disruption to production
APPROACH
A Rockwell Automation solution was installed, which included
RESULTS
Becuase the system runs from a central batch server, the customer has the ability to develop recipes away from the factory floor or off-site for ease of deployment,. This reduces batching errors that may be caused by operators
With the SINAMICS Smart Access Module, you connect wirelessly your mobile devices (smartphone, tablet, laptop) via WiFi to the SINAMICS Gconverter series. This gives you a powerful tool with numerous functionsfor wireless commissioning, diagnostics, and service.
The module is set up in just a few steps. No installation or downloading of additional software required due to the web server function.
A standard web browser and a commercially available operating system are all you need. The user interface of the SINAMICS Smart Access Module is simple and intuitive in its configuration and use. Read more here:
All images (c) Siemens Automation
Optima are an approved Siemens Drive Systems Integrator with a 30 year track record of delivering results on complex automation applications
A coating machine installed in 1988 was facing increasing reliability and operational challenges due to its age. Key issues included:
Solution:
The customer needed a comprehensive solution to address the following:
Benefits: Following the upgrade, the machine achieved several substantial improvements, making it one of the most energy-efficient unit in the factory, even outperforming newer equipment.
We are pleased to offer turnkey solutions to our clients. Depending upon the client’s brief and the project scope we very often manage the full project, including mechanical engineering and electrical installation. We have select sub-contract companies with whom we work regularly. Alternatively, we will readily work with customer-nominated third parties.
Our project management skills and application experience are valuable assets in this discipline.
On any project the facilities that Optima Control Solutions Ltd. provide are:
Need more information? Browse various projects here. Our industry-specific pages also provide details about the control system projects we have completed over the years.
Optima were recently asked to advise on a safety guarding application for one of our customers.
There had been a number of false trips of the laser scanner causing the machine to stop. A plastic chain ‘barrier’ had been fitted as a temporary measure with instructions to operators to not breach the barrier whilst the machine was running.
The customer naturally wanted this rectifying as soon as possible. Optima carried out a service visit to site.
On the site visit, our engineer noted that the scanner was showing a code which indicated that the front screen required cleaning.
Once the screen was cleaned thoroughly the scanner did not show any faults or errors and was in normal run mode.
Further checks on the original software were made to ensure the scanner configuration met the requirements of the safety guarding application.
The diagrams to the left show the Warning Field configuration (Yellow) and the Protective Field (Red). Both of these were confirmed to be operational.
The warning field causes the klaxon to operate but does nto stop the machine. The protective field causes an emergency stop of the machine.
We did find some concerns that needed addressing.
1. None of the scanner safety circuit had been documented on any drawings.
2. Non-compliance with EN999 ‘Safety of machinery. This defines the positioning of protective equipment in respect of approach speeds of parts of the human body’. It includes a formula to be used to calculate the distance from a hazard that a safety zone must be triggered.
Based on the stopping times of the machine, the scanner was placed too close to the machine to be effective in an emergency.
We are working closedly with our customer to assist them with this application and help them achieve a safe and effective solution to this.
If you need any support with safety applications or other upgrades, please get in touch..
Microtach encoders, manufactured by SSD Drives for many years offered reliable transmission of sensitive high-frequency information in an electrically noisy environment.
The technology used a combination of an incremental encoder disk combined with micro-electronics to facilitate the use of single fibre optic transmission of the encoder pulses.
This gave a huge advantage of being able to transmit a noise-free signal over considerable distances.
However, time moves on and the Microtach is no longer available. The fibre optic cable, sending and receiving optics also degrade over time, affecting system integrity and reliability.
Fortunately, Optima can upgrade your ageing Microtach units with a modern equivalent that has exactly the same mounting arrangement. We also supply a new coupling with every encoder.
We use our own proven high-quality multi-sheathed cable to give the same reliable signal quality for the wired encoder equivalent. Distances up to 100 metres have been achieved with no signal degradation.
For this, or any other LINK hardware or software support, just get in touch. With over 100 years of combined experience engineering (and for some, designing!) the Link hardware, we have a solution for your obsolete hardware.
If you want to see how your machine or process is operating day in day out from anywhere in the world, where do you start?
An increasing number of companies are turning to remote cloud-based solutions for machine monitoring. Optima are pleased to offer our Cloud-based solution which keeps your automation hardware safely behind a secure firewall.
The video below shows a basic demonstration dashboard. If you would like to know more then please get in touch – we like to talk!
This video gives a very brief demonstration on how our Remote Access and Cloud Logging System can help you keep track of how your machine is performing. See when the machine is started, stopped, realise production metric data straight to your mobile, desktop or tablet.
We have been trialling our remote machine data dashboards #iot #industry4. These allow real-time data to be visualised from any PLC anywhere in the world to a PC, tablet or mobile ‘phone anywhere in the world! The system can communicate over 4G, Wi-Fi, or a direct Ethernet connection. From Kazakhstan (yes, we do have two units out there!) to Kendal (we haven’t got one there yet…), we have you covered for a very low monthly cost.
Our remote reporting dashboards which can send #production #reports by #email will shortly be ready for release.
With the increased risk of hacking of industrial devices becoming ever more prevalent Security Week – New Vulnerabilities Can Allow Hackers to Remotely Crash Siemens PLCs it’s not as simple as just hooking your PLC onto your local network.
Most of our clients prefer a SIM-card based system. The benefits of this system are that the equipment is always live whenever there is cellular reception available. Our range of antenna options mean that reception is possible even in the most remote locations.
For more information, please contact info@optimacs.com
Mark Lane.
Join Optima at the Siemens #Transform2022 Conference being held at the Manchester Central Convention Complex on 12th and 13th of July to explore how digitalisation of industry is being accelerated. For more information and to register for a complimentary space, see #Transform2022. Some of the key areas are:
Join Optima, your trusted Siemens Automation and Drives partner at this event. It is the largest event that Siemens have ever organised in the UK so it set to be an event that shouldn’t be missed!