Rotary Shear Machines Cut To Length Right Every Time

Cutting machines require absolute precision and control in order to produce exactly the same sheets of material (most often metals) without any defects. Optima has completed a number of complex projects involving control system design and upgrades for rotary shears.

The diagram below shows the control system principles employed by Optima’s control engineers for one rotary shear project.

The shear is controlled using a high performance brushless servomotor coupled to the shear blade using a low backlash servo gearbox. The servomotor is controlled using a Siemens Simotion controller and Sinamics servo drive.

The infeed nip rolls are controlled using a closed loop vector controlled inverter drive operating in torque control. This provides a controlled infeed strip tension to the shear blades.

A measuring wheel linked into the servo motion controller is used to provide a continuous measurement of sheet position to the motion controller which using this information calculates the relative shear positions and hence cut points.

The shear speed matches the line speed whilst the cut is being made and then ramps to a different speed which is dependent on the distance between cuts.

A programmable encoder is used to identify blade position for homing of the shear blade.

To facilitate easy communication, the shear control system Simotion controller communicates with the line drives control PLC using an Industrial Ethernet network.

There is a colour HMI (TP177PN 5.7” with Ethernet) for operators to enter operational parameters and for some diagnostic facilities. This allows: start/stop; cut length; infeed tension and shear status to be set and monitored when the shear is operated in stand alone mode.

A hardwired emergency stop and guarding system including self locking upstream and downstream knife and nip guards ensure safe operation of the shear. This is linked into the line emergency stop system. Safety category 4 (EN 954-1).

A maintenance pendent is supplied for adjustment / replacement of the shear blade. This allows shear blade jogging forward and reverse at very slow speed to enable accurate blade measurements and adjustments. Safety guards may be opened to gain access to the shear blades whilst the pendent is connected but the machine does not run in auto until both upstream and downstream guards are closed and the pendent has been removed

All electrical equipment is housed in a freestanding enclosure located adjacent to the shear frame, approx dims. 1200mm (w) x 2100mm (h) x 500mm (d).

Please, email us at info@optimacs.com or call us on +44 (0)1254 27 28 29 for more details

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Scalable motion control systems from Siemens and Optima

Optima are pleased to be able ot offer our holistic system approach for motion control applications in the field of basic automation

Using the single-axis servo drive systems, SINAMICS S200, S210, and the new controller SIMATIC S7-1200 G2 we are able to offer a competitive solution for Kinematics, Positioning Cams, Speed axis and a host of other functions.

SINAMICS S200, S210, and the new controller SIMATIC S7-1200 G2.

Performance and Scalability

• Enhanced processing power with dedicated communication performance and extended memory
• Supports up to 31 PROFINET devices and synchronized
program execution with PROFINET IRT
• High drive performance due to a fast current controller

Flexible machine safety

• A cost-optimized fail-safe safety hardware portfolio
• PROFIsafe communication for safe data exchange
between the controller and the drive system for safety
applications
• Drive-integrated basic and extended safety
functionality up to SIL3, PLe and Category 4

Efficient motion control

• Control of single axes, coordinated axes, and simple kinematics
• Integrated motion control technology objects simplifying
configuration
• Drive-integrated basic positioner function, SINAMICS EPOS

Increased data transparency

• Near Field Communication (NFC) for wireless access
to diagnostic and device data of the PLC
• SINAMICS Smart Adapter for wireless access between
the drive-integrated webserver and mobile devices or
to the SINAMICS Startdrive engineering software
• Drive-integrated webserver for easy commissioning

PLC and drive overview

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

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