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.

04/15/2010


Control Panel Design Contest

 

 

 

Watch the Control Engineering 2010 Control Panel Design Contest winner, a tutorial video from Specialty Tooling.

Scroll down to watch the Control Engineering 2010 Control Panel Design Contest winner, a tutorial video from Specialty Tooling, of Evansville, IN.

Link to information about submitting a video for the 2011 Control Panel Design Contest.

Ryan Johann, automation engineer, Specialty Tooling says panel design considerations include power consideration, isolation, drives, controls, communications, and layout for appropriate placement with minimum wiring.

Ryan Johann, automation engineer, Specialty Tooling says panel design considerations include power consideration, isolation, drives, controls, communications, and layout for appropriate placement with minimum wiring.

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."

Specialty Tooling control panel design saved about 25% on panel size, decreased wiring by 35%, and improved productivity by 15% by integrating safety.

Specialty Tooling control panel design saved about 25% on panel size, decreased wiring by 35%, and improved productivity by 15% by integrating safety.

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.

Panel design and component selection helped Specialty Tooling resolve related controls challenges.

Panel design and component selection helped Specialty Tooling resolve related controls challenges.

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 tools, such as these from Bosch Rexroth, help with control panel design, programming, and automation system integration, Specialty Tooling says.

Software tools, such as these from Bosch Rexroth, help with control panel design, programming, and automation system integration, Specialty Tooling 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.
Also contact:
Specialty Tooling 812.464.8521
www.boschrexroth.com
www.sercos.com
www.solahd.com

Video finalists for 2010 are available for viewing, below.

Submit a tutorial video for 2011 here:

http://www.controleng.com/events-and-awards/control-panel-contest.html


Advertisement

Phoenix Contact sponsors 2010 Control Engineering Control Panel Design Contest


cpv_ats_systems_150

ATS Systems Oregon

Flash suppression panel and

power distribution

 

Watch Here -2010 finalist

CPV Concept Systems

Panel Design by Concept Systems

Teamwork is key to compete and exceed
our customers' expectations

 

cpv_premiere_automation150

Premier Automation

The Art of Panel Building

at Premier Automation

 

Watch Here - 2010 finalist

cpv specialty tooling 150

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.

 

Watch Here - 2010 winner

 



No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
2015 Top Plant: Phoenix Contact, Middletown, Pa.; 2015 Best Practices: Automation, Electrical Safety, Electrical Systems, Pneumatics, Material Handling, Mechanical Systems
A cool solution: Collaboration, chemistry leads to foundry coat product development; See the 2015 Product of the Year Finalists
Raising the standard: What's new with NFPA 70E; A global view of manufacturing; Maintenance data; Fit bearings properly
Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
Cyber security cost-efficient for industrial control systems; Extracting full value from operational data; Managing cyber security risks
Drilling for Big Data: Managing the flow of information; Big data drilldown series: Challenge and opportunity; OT to IT: Creating a circle of improvement; Industry loses best workers, again
Migrating industrial networks; Tracking HMI advances; Making the right automation changes
Understanding transfer switch operation; Coordinating protective devices; Analyzing NEC 2014 changes; Cooling data centers
Upgrading secondary control systems; Keeping enclosures conditioned; Diagnostics increase equipment uptime; Mechatronics simplifies machine design

Annual Salary Survey

After almost a decade of uncertainty, the confidence of plant floor managers is soaring. Even with a number of challenges and while implementing new technologies, there is a renewed sense of optimism among plant managers about their business and their future.

The respondents to the 2014 Plant Engineering Salary Survey come from throughout the U.S. and serve a variety of industries, but they are uniform in their optimism about manufacturing. This year’s survey found 79% consider manufacturing a secure career. That’s up from 75% in 2013 and significantly higher than the 63% figure when Plant Engineering first started asking that question a decade ago.

Read more: 2014 Salary Survey: Confidence rises amid the challenges

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.