Tech or Treat! – An EDC partner and VFFS machine builder manufactured a machine to drop the right amount of the iconic candy corns into small hand-out pouches. EDC integrated Rockwell’s Compact Logix PLC and Kinetix 6000 series servos with a SERCOS network for high-speed multi-axis forming, filling, registration and sealing of the bags. Operators call up recipes for different sizes and filling combinations. A lot of technology goes into Halloween treats.
A Power Cable Manufacturer with a unique oil impregnation process needed to upgrade 50 year-old manufacturing and reporting methods. EDC provided an Allen-Bradley Control Logix PLC platform with Panel View Plus 1500 HMIs to sequence and control a myriad of valves and pumps. Pressures, flows, temperatures and vacuum are graphed using a Factory Talk View SE application, giving operators the ability to track process segments and ensure control recipes are executed per spec. A Transaction Manger with SQL Server interface was used to gather data and add context to the output generated for Crystal Reports. In addition to the obvious process control benefits, the manufacturer was able to shave days off a weeks-long process, improving throughput and scheduling.
Factory floor communications is in full swing. Manufacturers are finding hidden cost savings and efficiencies by drilling down to the bit level of their machine controls and adding context to data they collect. Whether you want to trend temperatures or determine a line’s Overall Equipment Effectiveness (OEE), EDC can help.
A Power Cable Manufacturer built a new Continuous Vulcanization (CV) Line. EDC provided 23 vector motors and drives, a 1000+ point PLC with remote I/O, 30 zones of temperature control, 10 HMIs and four communications networks. The PLC program controlled steam, nitrogen, pressurized water and maintained the tension of a cable stretched within a 450-ft catenary tube. In all, the cable traveled over 1500 ft from the pay-off through capstans, three extruders, the steam-filled catenary tube, cooling troughs, accumulators and finally to the take-up reels. Every piece of equipment or process that touched the cable along the way needed to be controlled, monitored and coordinated. The controls for this project were built at the EDC facility and installed and commissioned 1000s of miles away.
An adhesive tape manufacturer needed an on-site emergency PLC upgrade and their coating line was a complex machine with over 300 points of I/O, multiple oven zones and motor drives. EDC extracted the old program (from a completely different PLC manufacturer), wrote the new PLC ladder logic for a Compact Logix PLC and installed, wired and started up the line inside of one week.
Allen Bradley PLC 5, SLC500 (“Slick 500”)
Automation Direct 405 Series
Siemens S7-300, S7-400, S5, TI3/4/505
Is it time to upgrade? Maybe you’d like to get rid of all those knobs, dials and burned-out meters and consolidate everything into a color touch screen. Electronic Drives & Controls has a team of automation engineers with years of experience helping customers upgrade their equipment.
Some customers like having individual temperature controls, while others like the idea of consolidating all their zones into a PLC and touch screen. Both would agree that solid state relays are the way to go for switching the power elements. EDC can accommodate all varieties of temperature control retrofits.
PLASTIC STRAW MAKER – Their straws are colorful, but their machine controls were not. Ten separate temperature controls and displays were consolidated into one PLC. Operators now perform set ups, see actual temperatures and other process parameters on a user-friendly screen. Integration of recipes makes changeover time even shorter. All drives, controls and remote I/O communications are on one ethernet network.
If it’s picked-up or moved from one place to another, EDC has performed a VFD and/or controls retrofit on the equipment. From the everyday handling applications to the not-so-common.
Harbor Dredging Barge – EDC upgraded the barge crane’s VFDs and control logic for two winch systems. Working with power from an on-board generator and space constraints made this a very unique application.