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Case Study – From Old to New: Modifying a Legacy Dual Textile Spray Line into an Efficient Machine with Doubled Throughput

Posted on by Patty Davis

Heytex, a brand of the German-based Heytex Bramsche GmbH, is a global developer and manufacturer of high-quality technical textiles. Their portfolio includes sophisticated and unique products fabricated and engineered using complex textile technology, such as signage, banners, boats, sales, barriers, and other technical textile products for a variety of customers. Electronic Drives and Controls (EDC), a recognized leader in the design, upgrade, and service support of drive and PLC Systems, recently helped Heytex significantly improve industrial textile coatings equipment for a military customer and double their overall production capabilities. 

Problem

Heytex had previously purchased a used paint line machine at auction that consists of two parallel production lines sharing the same painting booth and oven sections which could run concurrently or separately. However, one of the lines (Line 2) sat idle for approximately three years before Heytex sought help improving its operability to produce spray-painted industrial camouflage textiles for a military customer. Parts from Line 2 were scavenged to keep Line 1 running.

Originally, Heytex would receive an AutoCAD file from their military customer that specified the geometry of the desired pattern to be painted by the machine. Each line has six drives: 3 VFDs for web handling and 3 servo drives to traverse the paint heads. The process begins by feeding industrial fabric through a conveyor from an unpainted fabric roll. Next, three spray heads move across the fabric in a coordinated fashion applying green, brown and black paint resulting in a specified camouflage pattern. The machine then dries the fabric in a tunnel oven and rolls it into a finished painted textile roll.  

As purchased, each section of the machine used a personal computer with an obsolete Windows XP operating system and a soft Allen Bradley Programmable Logic Controller (PLC) for the unwinding and painting of the fabric. Two physical Omron PLCs handled downstream control, one for the oven and conveying systems and another on the rewind section. A proprietary software run on the XP operating system utilized algorithms to control the paint from the spray heads and help to convert the customer’s CAD files into control commands, a very cumbersome process requiring much manual intervention.

Another problem impeding the retrofit plan was a tremendous lack of documentation and labeling. This coupled with obsolete controls, proprietary software and a burdensome workflow with no known support prompted Heytex to task EDC with improving the machine with an integrated hardware and software design.  

Solution

EDC’s approach was to streamline the control architecture ensuring that the PLC, drives and HMI were from the same manufacturer and would all be on the same communications network. Three disparate control programs were consolidated into one PLC, eliminating the need for a machine-based computer, soft PLC and monitor. The Siemens S7-1500 PLC and S120 drive platforms coupled with a 12-inch Comfort Panel were an excellent fit for this application. 

Siemens’ S120 Sinamics Smart line module and common DC-bussed drives provide energy saving load sharing across the six drives and is able to regen excess AC voltage back to the incoming power line. Line drives were previously controlled in a start/stop mode and could only run at other speeds by manually changing the internal drive parameters. The S120 system provided full speed control capabilities as commanded by the PLC over a ProfiNet network.

The S7-1500F failsafe PLC simplified safety component wiring, especially given that three new cable-operated switches (safety rope pulls) were installed at the Unwind Exit, Paint Booth Entry and Rewind, improving the overall safe operation of the line. All main control components communicated with the PLC over a single ProfiNet control network including six VFD and servo drives, two remote I/O hubs and a new 7” HMI located at the Rewind section.

In addition to the cable-operated switches, other mechanical upgrades included a specially designed tension control system for the Unwind, adapters to couple new servo motors to existing spray head linear actuators, a line speed encoder at the oven exit and a linear position transducer for accumulator feedback. The EDC Field Installation Team installed and wired the new elements on Line 2 and ensured their proper functionality.

As previously mentioned, EDC consolidated all PLC logic into one CPU that closely communicates with the new HMI and S120 drive system. A user-friendly HMI screen and a recipe system were incorporated to improve the operator’s experience running the line. An offline program to convert the customer’s CAD files to data the PLC could use for proper control of the spray heads was a crucial part of the upgrade. EDC’s Project Engineer wrote an open-source Java script/HTML interface that could be modified by anyone with those computer language skills, eliminating the proprietary nature of the previous software incarnation.

Another key element of EDC’s retrofit is their documentation. A full set of wiring schematics was created that included reference for all components, wire numbers and a terminal plan. The customer was given a physical binder with hard copies of the drawings and digital copies of the control programs, the CAD conversion program and component manuals. A Tosibox remote access module was installed and connected to the machine’s control network. When connected to the internet, this device provides an ultra-secure VPN tunnel for remote monitoring and troubleshooting.

Impact

The improvements EDC made on Line 2 were substantial. Heytex went from a non-operational line whose parts were being cannibalized to keep an adjacent line running to a fully functional, efficient line with a state-of-the-art control system. Improvements included:

  • Streamlined workflow making it easier to go from the customer’s drawing to product runs, eliminating a full set-up step
  • Open source programs that can be modified and improved by any qualified service provider, eliminating proprietary software
  • An energy-efficient control architecture that is rugged, orderly and fully documented without reliance on ever-changing personal computer hardware
  • Improved control of the Oven conveyor, Tensioner and Rewind motors including better accuracy and synchronization through all speed ranges 
  • Improved Accumulator control that prevents finished product from touching the floor as was the case during Rewind roll changeover
  • User-friendly operator interface screens with more relevant operational feedback, alarms, messages and maintenance screens 
  • New capability to switch between patterns in the middle of a single roll and stop and resume a pattern if there is an Estop or alarm, potentially saving hundreds of yards of material per year
  • Remote monitoring and troubleshooting capability which was utilized to its full potential one month after start-up when Heytex needed to recalibrate Line 2 for new material. EDC was able to support them remotely and avoid a costly service trip from New Jersey to Virginia.
  • A retrofit platform with documentation, programs and drawings that can be utilized to upgrade Line 1, ensuring production viability for years to come

To sum up the benefits of the project, EDC’s VP of Engineering Chuck Dillard said, “If you look back, only Line 1 was operable. Now both lines are running, and Line 2 runs more efficiently with higher throughput than the machine’s original design.”

Overcoming Supply Chain Issues in Automation Through Flexibility

Posted on by Patty Davis

Since the start of the Covid-19 Pandemic, supply chain issues have been on everyone’s mind. It’s a universal problem that is not industry exclusive and has progressively gotten worse in 2022 as demand has soared.

The automation industry today seems to be at its wit’s end. Everyone needs parts, but parts aren’t available. Deadlines are getting pushed back. Lines are down. It’s getting harder and harder to put out these fires. 

Below are methods that Electronic Drives and Controls has employed to better tackle these supply chain issues and bring their clients relief.

Stay Early, Stay Ahead 

Evolution during a crisis is imperative to a business’ survival, so it will come as no surprise that many integrators have made certain changes to keep up with the ever-changing tides. EDC has always been creative in their problem solving, so it was an easy pivot for them to make a slight change in their project planning by sourcing parts as their first step, or as early in the process as possible.  

“On the front end of an upcoming project’s discussion, we tend to now look at availability of parts even before we start our engineering process. We used to engineer it, then find out that certain parts were not available, and then we would have to re-engineer it if we wanted to meet a particular delivery,” said Chuck Dillard, vice president of EDC. “Now, it’s a lot of coordination between our purchasing and engineering departments to pick the right parts and design around what’s available.”

Through front end work on a project, engineers can predict pitfalls and pivot where needed. Having an early plan and changing where needed is better than coming in later and improvising when challenges arise. This flexibility can be crucial during supply chain constraints.

Utilizing Third-Party Manufacturers

EDC has also turned to third-party manufacturers to help address challenges. Third-party manufacturers can be difficult to choose from and it takes extensive research, time, and experience to understand how to credibly source parts. When you’re on your own, there are quality and safety concerns to consider when ordering off of the web – that’s why EDC has invested the necessary time and effort to research and connect with the right sources. 

“For instance, if we want to get an Allen Bradley PLC, we go to Turtle & Hughes and we place an order with them. They order from the factory and then the factory says, ‘Oh, that’ll be four or five months,’ but we really need that PLC right away,” said Bob Pusateri, director of business development at EDC. “So, we purchase components from alternate sources.”

EDC keeps a well-researched list of possible sources in their back pocket to acquire parts as quickly as possible. They rely on their proven expertise to discern whether a part will be usable, even from somewhat-controversial online auction sites like eBay. They don’t make any sourcing decisions lightly, and they always employ a proper investigation before committing to a purchase. With the risk of faulty seals, or other safety measures at stake, working with an industry expert like EDC is crucial to ensuring the successful delivery of these hard-to-find items.

A Vendor-Neutral Strategy

As a system integrator and field service team specializing in over 40 drive brands, Electronic Drives and Controls maintains a vendor-neutral strategy, meaning they do not prescribe to only one OEM for all their projects. This has allowed the company to be more flexible and pull from an array of manufacturers. In turn, EDC is able to compare pricing and capabilities between vendors, allowing them to pass along the added value to their customers. 

Having strong alliances with world-class hardware and software providers around the nation, EDC has done the background work to ensure that their customers are getting the quality that they have come to expect. Through good relationships and a strong network, EDC has lowered lead times and sourced parts that would have otherwise been inaccessible.

The Benefits of Mixing and Matching

With an ample and extensive network of contacts, EDC has the added benefit of being able to pull parts from multiple resources when they’re ready, and as soon as possible. By utilizing a vendor-neutral approach, EDC is able to ‘mix and match’ parts for systems. By sourcing appropriate parts from alternative resources, EDC is able to better maintain project timeline expectations, allowing projects to be completed faster and with much less downtime.

In addition, through mixing and matching, the more cost-effective alternative can be purchased. Using one OEM for the HMI and another for the PLC offers the option to now choose the less expensive parts. This can also help cut down on the time needed to make a purchase, which means more time is going into actual engineering for the project.

What Does the Future Hold for the Supply Chain? 

Last summer, if you had asked a supplier when they expected the supply chain to start improving, they would have most likely estimated the summer of 2022. Yet, as most of us well know, that time has come and gone, yet supply challenges remain. 

Today, there is a mixed review, with some saying it’s getting better, and some of the opinion that it’s getting worse. This unpredictability can understandably be worrisome, but it is not cause for panic. 

When you’re stuck with downtime that is troublesome or you can’t get parts for the system that you rely on, EDC is proud to be your warranty. The supply chain is scraping the bottom of the barrel and the outlook is uncertain. Call on EDC, an experienced and knowledgeable integrator, to navigate this volatile landscape and make conscious decisions on your behalf. EDC has the resources to get your systems up and running.

Start a conversation with EDC here to source the parts you need today!