Metal Decorating Press Upgrade using Siemens Simotion S120 + D425 controller + Simatic S7 PLC

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
  • Circuit diagrams
  • 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.

Automax and PLC5 to PowerFlex Drives and Control Logix Upgrade

Obsolete AutoMax Rack

Optima recently carried out an upgrade on a complex Automax-based drive system running on an obsolete PLC5 controller. The customer requirement was that the old Automax controller rack, PLC5 and obsolete DC drives were  removed in one complete shutdown and replaced with the latest state-of-the-art technology.

Optima achieved this by replacing the DC drives and motors were by  new AC Powerflex 753 drives and AC vector motors. Additionally, the PLC 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 included:

  • Hardware calculations/rating for drives
  • Customer project specifications
  • Project design specification
  • Circuit diagrams
  • Special test documents
  • Software specifications and sequence diagrams
  • Installation of new panels and motors on-site

    New Control Logix PLC and PowerFlex Drives Panel

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: Mark Lane, Michael Hill or Andy Coverdale on 01254 272829 to discuss your requirements in more detail.