Innovative Automation Integration for Advanced Laminator Machine
VELOX COMPLETES LAMINATOR MACHINE AUTOMATION PROJECT WITH SEAMLESS SYSTEM INTEGRATION
The Challenge
The customer used a machine initially built in the United States as the foundation and redesigned it in India. They wanted to integrate an entire Siemens portfolio, including the highly advanced Siemens S7-1500T controller, along with the S120, V90, and G120 drives. All operations are monitored using the WinCC Unified WEB-based HMI, which emphasises its essential role in system control. This decision posed the challenge of developing accurate logic in a limited timeline while assuring seamless system commissioning. They also had to integrate an old Unwinder station PLC panel with the newly designed machine. A significant technological challenge was achieving precisely cutting of the PE web as it drove through many rollers and was controlled by a high-precision servo motor-driven rotary cutter, emphasising the importance of accurate product cutting.
The Solution
- Velox collaborated from the beginning of the design process, focusing on understanding the machine's requirements and selecting the controller, drives, motors, and HMI system that delivered complete integration and high-performance functionality.
- During the design phase, Velox was involved in selecting the S7-1500T system for precise motion control and synchronized axes. This choice was guided by the system's built-in motion control capabilities, which enabled servo control. The S7-1500T's high processing power, large memory capacity, and fast communication interfaces were crucial factors that made it ideal for the application.
- Velox implemented the WinCC Unified HMI panel, which includes HTML5-based web clients for web-based visualisation, Excel-based reporting, and a modern, intuitive user interface. The system was created to improve user experience and efficiency while focusing better security measures against cyber-attacks.
- The overall design of the electrical system, which includes PLCs, servo drives, servo motors, and servo cables.
Why Velox Solutions Makes Sense
- Early Engagement in Design: Velox worked closely with the client from the beginning of the design process. This early engagement enabled Velox to gain a complete understanding of the client's needs and operational goals, providing the groundwork for efficient system development and integration.
- Swift Commissioning: By integrating the Siemens S7-1500T controller and undertaking rigorous offline testing throughout the development process, Velox guaranteed that the system was perfectly tuned to the client's needs. This proactive strategy reduced difficulties during commissioning, allowing the client to begin production of commercial sample materials only six days after system deployment.
- Enhanced Efficiency and Reliability: Velox's technological capabilities, particularly in advanced controllers and automation systems, greatly improved system efficiency and reliability. This not only accelerated production start-up, but also enhanced overall operational performance, providing the client with long-term productivity enhancements.
- Velox's commitment to sustainable practices extends beyond technological innovation. Velox reduces environmental impact by optimising system designs and implementing energy-efficient solutions, while increasing operational efficiency. This method not only reduces carbon footprints, but also assists businesses in meeting their sustainability objectives, ensuring a better future for industries globally.