As we move into a new decade, we at Control Works wanted to take a moment to look back at some of the exciting projects completed in 2019. Here are just a few of the projects we completed that helped our customers modernize their controls, decrease downtime, increase throughput and simplify diagnostics and trouble shooting.
Coil Slitting Line Retrofit
Doubled Line Speed and Increased Uptime
Our client came to us to update their coil slitting line. The retrofit included replacing the original DC drives and motors with AC drives and motors. Ultrasonic sensors maintain the coil loops. Real-time laser sensors measure the diameter of the coils as the material is pulled through the slitting station, to achieve real-time speed matching of the coils.
We combined ultrasonic and laser-based diameter measurement to achieve line speeds up to 650 FT per minute increasing the overall throughput by 100% effectively doubling the line speed of the old system. We further increased overall up time via easier system startup and built in system diagnostics. ROI on this project was less than 6 months.
As part of this coil slitting retrofit, we replaced the outdated, messy control panel with a well-designed and documented panel.
Pacific Press Brake Retrofit
Updated Controls and Streamlined Electrical Panel
For this project, we completed a retrofit for our customer’s 10-foot, 230-ton pacific press brake with Y1, Y2, X, R and a programmable moving finger for X1.
Over the years, this machine was modified several times. The result was that the electrical controls were cumbersome and split between three separate electrical panels.
We modernized the controls with a new Cybelec ModEva Pac control system, new servo drives and motors for the three-axis back gauge. We also streamlined the machine by removing the three separate panels and consolidating the electrical into a single panel.
The result of this press brake retrofit is an up-to-date machine that will provide reliable and easy-to-maintain service for years to come.
For this project, three separate panels were combined into one, modern, easy-to-maintain panel.
LVD Press Brake Retrofit
Simplified Fault Finding and Trouble Shooting
We completed this retrofit on a 16 ft, 165-ton LVD press brake with Y1 Y2 and a six-axis back gauge.
The client came to us to modernize their control panel. They also wanted to simplify fault finding and troubleshooting. The press brake was significantly modified since its original construction, and the modified control system and electrical panel were not well documented. This made fault finding and troubleshooting very problematic.
We installed a new Cybelec ModEva 19T touch control system, and an HMI for mode functions on the machine. This solution included several features that significantly improved the customer’s ability to trouble-shoot their press brake. The HMI has built in software for the machine inputs and outputs to be visually verified for fault finding. Additionally, when the machine is connected to the network/internet it’s possible to perform remote diagnostics.
The HMI is also enclosed in a magnetic enclosure. This allows the operators to attach it to the press beam so all functions and modes of operation can be selected without walking to the electrical enclosure.
The outdated controls weren’t well documented which created issues with troubleshooting. The new control panel makes maintenance considerably easier.
Bakery Packaging Line
Decreased Downtime
Our customer came to us to better utilize their cookie packaging equipment. Their line consisted of five wrappers, only three of which were utilized at a time. The remaining two wrappers were for backup. Control Works designed, built and wrote software to create a more efficient system. Now if a packaging line goes down (malfunction or out of wrapping material), the system automatically diverts the product to one of the open machines. This has led to a significant decrease in downtime and an increase in overall product throughput.
We revamped this bakery packaging line with new software and controls. This led to less downtime and a more efficient system.
Replacement Servo Drives and Motors
Decreased Downtime and Maintenance Expense
This customer came to us because they were having problems with obsolete servo drives and motors, Replacement parts were becoming increasingly difficult (and very expensive) to source. Having the old units repaired was time consuming and resulted in significant machine downtime.
We replaced the old servo drives and the machine has been running trouble free ever since.
Obsolete servo drives and motors meant wasted time and money to find parts and maintain equipment. For this retrofit, we replaced the servo drive and motor, saving considerable time and money.
2020 is already shaping up to be a great year and we look forward to helping many more customers improve their manufacturing. Contact us to see how we can help you.
