Machine builder wins control panel design contest: 60% less space, 30% less wiring

CP Packaging won the 2009 Control Engineering panel design award, based on a poll at www.controleng.com during March. The company’s design for plant-floor machine control panels focus on saving space, assembly, and startup time as key considerations, especially in rugged environments. This and five other panel design tutorial videos remain available for viewing and comment. Look inside the CP Packaging panel design and the others, as well.

04/14/2009



In the CP Packaging control panel, controls and I/O modules are on top, terminal blocks in the middle, and high-voltage components on the bottom. CP Packaging Control Engineering Panel Design video .

Oak Brook, IL, and Appleton, WI – Winner of the 2009 Control Engineering panel design award is CP Packaging . The company’s design for plant-floor machine control panels focus on saving space, assembly, and startup time as key considerations, especially in rugged environments.
Explaining the company’s VisionPak Horizontal Form-Fill-Seal Vacuum packaging machine, CP Packaging’s Ray Buchko Jr., vice president of operations, said the control panel was designed to reduce space on the machine, provide easy access for maintenance, reduce costs, and save build-out and installation time. “In the environment where these machines are used, the panel also had to be durable enough to withstand high-pressure washdown, so designing for sanitation was also important.”
The design removed the servo drives from the cabinet and distributed them onto the machine. “That change saved about 60% in control cabinet space, and 30% in wiring costs,” Buchko says. Because the Rexroth integrated motors and drives are connected by one cable (instead of the previously required 12), adding more drives won’t change cabinet size, since the extra drives are located out of the machine. Servo power supply is mounted sideways to reduce the cabinet depth, he noted.


Access was cited as a strong feature among those commenting on the CP Packaging VisionPak Control Panel video in the comments area where tutorial videos are posted.

Finished back panel is bolted into a water-tight, high-pressure washdown stainless steel enclosure that swivels out from the machine. With small size and low weight, the panel for a seven-axis machine can be lifted into place by one person. Mounting the panel on the machine (instead of remotely) saved time on wiring and installation. Even the location adds to the machine design. The swing-out panel, which Buchko calls unique, serves as a machine guard and eases access behind the panel and under the machine.
Inside the panel
The enclosure (see photo) design includes high voltage and control components. On top there’s the control wiring: main controller, I/O modules with spring cage terminal connections, and other controllers. On the bottom is the high-voltage wiring. In the middle, terminal blocks connect above and below using insulation displacement technology to save time and keep the integrity of the landing points to avoid shorting. In addition, DIN-rails are used as much as possible to help save time.

CP Packaging VisionPak Horizontal Form-Fill-Seal Vacuum packaging machine

More information on the CP Packaging VisionPak Horizontal Form-Fill-Seal Vacuum packaging machine is available here: www.cppac.com/go/visionpak .

Simpler panel design means assembly is possible in hours rather than days, with easier maintenance and troubleshooting. Mounting the panel on the packaging machine helps reduce onsite installation and startup to less than 24 hours, as opposed to several days.
In addition to the team at CP Packaging, Buchko also credits Marty Paschke, Machine Control Specialists , Little Chute, WI, for "initial layout of the panel and component locations to minimize the size of the panel and still maintain separation of low and high voltage wire points." Wade Savage, CMA/Flodyne/Hydradyne , Brookfield, WI, "helped source the components that provide the flexibility we require to manufacture custom machines with a single enclosure." Key components were provided by Banner Engineering , Bosch-Rexroth , Moeller , and Phoenix Contact .
Panel design voting criteria
Suggested criteria for voting on the control panel videos focused on how well the videos explained:

  • The thought process for determining the layout of components, both interior and exterior component mounting techniques;

  • Wire and cable termination techniques;

  • How consistency is maintained from one person to another in component mounting and wiring practices;

  • Door work (mounting, labeling and wiring of devices on an enclosure door, or other exterior surfaces);

  • Methods for insertion of completed panels into enclosures;

  • Methods for maintaining cleanliness and protection of the enclosure and components; and testing procedures.

“That’s a lot to pack into a panel design video in five minutes,” noted Control Engineering ’s David Greenfield, editorial director. “While all six continue to garner interest, voters clearly put CP Packaging on top.”
See more photos and read more details about this CP Packaging application from the May 2009 Control Engineering North American print edition. Control Engineering is located in Oak Brook, IL; CP Packaging in Appleton, WI.

Videos remain posted for viewing and comments .

 

Submit a video for the 2010 contest - Learn more here.

- Mark T. Hoske , editor in chief
Control Engineering News Desk, www.controleng.com
Register here to select your choice of free eNewsletters.





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...
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
Inside IIoT: How technology, strategy can improve your operation; Dry media or web scrubber?; Six steps to design a PM program
World-class manufacturing: A recipe for success: Finding the right mix for a salad dressing line; 2015 Salary Survey: Manufacturing slump dims enthusiasm
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
Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
Warehouse winter comfort: The HTHV solution; Cooling with natural gas; Plastics industry booming
Managing automation upgrades, retrofits; Making technical, business sense; Ensuring network cyber security
Designing generator systems; Using online commissioning tools; Selective coordination best practices

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.
click me