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...
World-class maintenance: The three keys to success - Deploy people, process and technology; 2016 Lubrication Guide; Why hydraulic systems get hot
Your leaks start here: Take a disciplined approach with your hydraulic system; U.S. presence at Hannover Messe a rousing success
Hannover Messe 2016: Taking hold of the future - Partner Country status spotlights U.S. manufacturing; Honoring manufacturing excellence: The 2015 Product of the Year Winners
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Digital oilfields: Integrated HMI/SCADA systems enable smarter data acquisition; Real-world impact of simulation; Electric actuator technology prospers in production fields
Improving flowmeter calibration; Selecting flowmeters for natural gas; Case study: Streamlining assembly systems using PC-based control; CLPM: Improving process efficiency, throughput
Putting COPS into context; Designing medium-voltage electrical systems; Planning and designing resilient, efficient data centers; The nine steps of designing generator fuel systems
Warehouse winter comfort: The HTHV solution; Cooling with natural gas; Plastics industry booming

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

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.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me