Tag Archives: HMI

Yaskawa Servo Controller Streamlines Extrusion Die Adjustments

Posted February 5, 2016 by Pepper Hastings

Categories: Blog, Parker, Yaskawa

Tags: , , ,

One of our clients needed a solution for automatically adjusting his horizontal extrusion die. The die controls the thickness of a plastic web about 72 inches wide.

Previously, the 72 bolts across the top of the die were adjusted by hand by an operator. The worker would compare the readings on a nuclear micrometer to what the set point was. This was labor intensive and required a lot of the operator’s attention, time he should have been dedicating to watching the machine and its operation.

Servo controllers, motors and Modbus solved a die adjustment problem on this extrusion machine.

Servo controllers, motors and Modbus solved a die adjustment problem on this extrusion machine.

Our solution was to incorporate a Yaskawa multi-axis servo controller with four servo amplifiers and motors and Modbus communication to interface with their micrometer.

A brief explanation: Two motors are mounted on two “heads.” Each head consists of:

  • A position motor with a gear reducer that travels on a linear gear across the die
  • And, an adjusting motor with a socket mounted to the motor shaft that pneumatically lowers down on a bolt to adjust it.

Each head is taught the position of the first bolt by moving it manually to that position. The distance between each bolt is inputted into the system through the Parker HMI. Then each head travels across the die, learning the positions of every bolt and the rotational position of each bolt head. In case of vibrations or other external influences to the bolts, the system has the ability to relearn on the fly the rotational position of any bolt.

The micrometer will message the servo controller via Modbus when a portion of the web is out of tolerance. The servo controller is told which bolt is causing the error and by how much. The “head” closest to the offending bolt will move to a bolt 3 bolts away. Then, alternating between bolts on either side of the offender, the head start adjusting the bolts. The outside bolts receive minor adjustments working up to a full adjustment on the center (and offending) bolt.

Result; the operator can manage the machine and not have to micromanage a bunch of bolts.

Bissell

Productivity up. We do solutions like this for customers every month. If you tell us y

our problem, we probably can help your efficiency.

Stewart Bissell is a Field Applications Engineer in Innovative-IDM's Dallas office. He can be reached at stewart.bissell@iidm.com

 

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Hydraulic Presses Improved With PLC and HMI

Posted December 22, 2011 by Pepper Hastings

Categories: Omron

Tags: , ,

by Rami Hassouneh, Innovative-IDM Application Engineer

Overview:

A plastics manufacturer suffering from poor productivity, inefficiency and a large number of operator errors acquires an automated solution to alleviate the problem. Using a simple setup with an Omron PLC and Omron HMI, the manufacturer reduces wasted time and material and utilizes his hydraulic presses to their full potential.

The Challenge:

The process in question was a fully manual process. It consisted of an operator filling a mold with resin, setting the pressure, and activating the hydraulic press. The operator would wait for a given time as indicated in the “recipe”, then increase the pressure setting. The operator, again, would wait for a given time, and then disengage the hydraulic press. The mold is flipped over and the process repeated. The total time of production for one part could run from 30 minutes to 300 minutes depending on the resin composition and size of the finished product.

This type of process, while simple in nature, is actually inherently prone to productivity issues. The process relies completely on the operator to accurately set and control variables such as pressure and pressing time. Human error, and unfortunately a lack of care by the operator, was resulting in these variables being inaccurate and ultimately many parts were rendered useless. On a typical day the manufacturer had 10 presses running, and was losing 2 parts a day due to operator error, at an average of $175 per part.

The Solution:

Our solution was to automate the process by installing an Omron CP1H PLC and an Omron NS series Industrial Touch Screen HMI on each press. The operator from then on would only need to select the “recipe” from a user friendly menu on the HMI, and press start. The PLC from them on would control the process by starting the hydraulic press, setting the pressure required, and time to hold. It would alert the operator when the process was completed either to flip the part over, or to remove the product. It also would trigger an alarm if a mechanical failure had occurred in the press and the set pressure could not be achieved.

The total cost for setting up the system, allowing for programming, hardware, and installation was $130,000.

 

The Results:

The manufacturer eliminated the losses due to defective products coming out of the presses. While that alone would have covered the cost of the automated solution in approximately one year, and directly increased his revenue by $127,750/yr from then on, there were also added benefits that became apparent. Productivity was increased as now a visual alarm allowed the supervisor to quickly see when a press was sitting idle, and the situation corrected immediately. The solution provided also reduced the manpower required to run the ten presses from five operators to two.

Materials Used:

OMRON CP1H Series PLC with Ethernet Interface.

OMRON NS Series Industrial Touch Screen HMI, 8” with Ethernet Interface

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