Control Panel Design Contest
2010 winner of the Control Engineering Control Panel Design Contest is... Specialty Tooling Inc., Evansville, IN. View the finalists, learn more about the winner, and link to information about submitting a video for the 2011 Control Panel Design contest.
The end-user is a major appliance manufacturer. The application is a machine that applies bends and twists to the tubing on the bottom of a refrigerator. The controls challenge was to reduce wiring, cabinet space and eliminate the 90-minute hard tooling change-over. Among four finalists that submitted tutorial videos on control panel design in 2010, subscribers voted online to select machine builder Specialty Tooling's tutorial video as the winner.
Ryan Johann, automation engineer, explains: "When I'm laying out control enclosures, my thought process is,‘Where is it going to be easiest to bring my I/O cabling in from the machine, what kind of components do I need to have with 480 V ac, 3 phase, or 24 V dc? What's the supply power? What kind of drives, controls, and communication cables do I need? And how can I think about how to isolate the highand low voltage, to keep noise out of the equation."
The control cabinet needs to be laid out to ensure everything is placed appropriately.
Enabling tools included Bosch Rexroth's MLD-M control architecture. For the 4-axes application, Johann sought to reduce panel size. One master axis, with integrated PLC and motion control functionality, reduces the need for an external PLC that would take more panel space. The drives save space, wiring together with one wire, in a daisy chain, to SERCOS III I/O blocks.
Another space saving technique is having one point to terminate up to a three-wire sensor thus reducing the amount of wiring and time needed to assemble the panel.
A more traditional architecture would have required additional wiring to an external PLC or motion controller with I/O cards back to a separate portion of the panel. The Specialty Tooling control panel design saved about 25% on panel size, decreased wiring by 35%, and improved productivity by 15% by integrating Bosch Rexroth's Safety-On-Board technology. Ordinarily the operator would need to drop the 480 V ac power to the drives in the work cell to load and unload the part. MLD Safety on Board technology meets safety requirements by putting the drives into a safe stop condition when the operator is in the work cell, Johann says.
Software from Bosch Rexroth helped Specialty Tooling program, integrate, and execute all project components, including PLC and motion programming, human-machine interfaces, and I/O connections.
Good tools help a smart design.
Thanks to all participants and voters, and 2010 contest sponsor, Phoenix Contact. Scroll down to link to videos and more information. Leave your comments or advice online.
Specialty Tooling 812.464.8521
Video finalists for 2010 are available for viewing, below.
Submit a tutorial video for 2011 here:
ATS Systems Oregon
Flash suppression panel and
Panel Design by Concept Systems
Teamwork is key to compete and exceed
The Art of Panel Building
at Premier Automation
Specialty Tooling Inc.
With integrated motion, logic, control and Safety-On-Board drive technology, Specialty Tooling's control cabinet design is 25% smaller with 35% less wiring costs and 15% higher machine productivity.
Case Study Database
Get more exposure for your case study by uploading it to the Plant Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.
These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.
Click here to visit the Case Study Database and upload your case study.
Annual Salary Survey
In a year when manufacturing continued to lead the economic rebound, it makes sense that plant manager bonuses rebounded. Plant Engineering’s annual Salary Survey shows both wages and bonuses rose in 2012 after a retreat the year before.
Average salary across all job titles for plant floor management rose 3.5% to $95,446, and bonus compensation jumped to $15,162, a 4.2% increase from the 2010 level and double the 2011 total, which showed a sharp drop in bonus.