A complete electronic retrofit
of 11-elements packaging press with two unwinder and inline laminator.
Developed with Siemens Simotion technology & industrial PROFINET networks.
Obsolete Eurotherm Link I/O stations, AC Drives and operator Panels were more than 20 years old, these were connected via problematic fiber optics that caused significant downtime.
Everything were upgraded with Siemens Automation Integrated systems.
The new automation software was made with data structures and modern tasks with logic blocks / motion blocks / subroutines / functions, all the link module logics was traslated into new PLC maintaining the original functionality.
The new SCADA system was redesigned, maintaining the original functions with new graphics and interfacing with the new S7 Plc’s and to the company’s MES system for compatibility according to “Industry 4.0” requirements.
Here’s some images of the machine (BEFORE / AFTER ):
MAIN CONSOLE: The old SCADA system was partially broken (only one worked). Now is revamped with new Siemens Industrial PC’s and Siemens high resolution Touch Screens, running two Aveva InTouch SCADA ver. 2023R2 (latest).
MAIN CONSOLE CABINET: The back of the main console Before and After shows the upgrade improvements, both new InTouch SCADA systems are powered by intelligent UPSs that automatically perform shutdown operations, preventing data loss.
SECONDARY UNWINDER: The old and problematic Eurotherm non-regenerative SSD drives, which dissipated excess energy through resistors, were replaced with Siemens AC drives with regenerative DC BUS power supplies that recover energy and make it available.
UNWINDER’S OPERATOR PANELS: New Siemens KTP700 operator panels have been designed maintaining the graphics and functions of the original Eurotherm SSD panels in order to facilitate operators avoiding further instructions.
PLC & IO/RACKS: Twenty-one obsolete Eurotherm SSD fiber optic Linked I/O Racks and PLC’s, have been replaced with new S7 PLCs and Siemens ET200SP-Profinet remote racks. The entire network now uses SCALANCE X industrial managed hub switches.
MAIN MOTOR CABINET: The electrical cabinet for the main motor and the motors of the independent elements and laminator is designed with a single big regenerative DC BUS power supply (right) and high-performance drive modules.
MAIN UNWINDER: The old non-regenerative Eurotherm SSD drives, which dissipated excess energy through resistors, were replaced with Siemens AC drives with regenerative DC BUS power supplies that now recover energy.
STARTUP: After installation and testing, the machine returned to full production. The operators noticed nothing using the press as usual.
IN SHORT:
all the old hardware, obsolete and no longer available has been completely replaced by the most modern Siemens devices, as well as the software has been rewritten with the more modern programming languages.
Thanks to the improved dynamics of the new drives and the high reliability of the new electronics, the press is much more productive.
Together with the improvements and also thanks to the complete remote control, the result is a press that can be diagnosed and repaired in short times as the components are up-to-date and easily available.
Thanks to the careful attention paid to reproducing the machine’s operation, the operators were able to start working with the rebuilt machine without any further instructions.