Motion control: Packaging machine builder saves with servo system, controls upgrade

Siemens Simotion Shaftless Drive Standard software helps machine builder gain 50% savings on components and 30% savings on control cabinet footprint with comparable performance.




Siemens Hycorr Maxco packaging machine builder

This Hycorr rotary die-cutter, shown with four print stations, dwell section and die-cut section, is in use at a major supplier to the corrugated and packaging market segments.

Fred Harrison, president of Hycorr Machine Corp., has always believed in being first. Never one to rest on his laurels, the Kalamazoo, MI builder of corrugated boxmaking machinery recently put his engineering team on the task of improving the overall controls package on the company's line of rotary die-cutter machines. In particular, the servo system and controls package needed upgrading with newer technology. The previous technology functioned properly, but Hycorr engineers sought greater cost containment and a reduced footprint, with no loss of performance.

After considerable research, and based on the direct experience of a recently hired engineer, Hycorr began its investigation of a totally new system, one that would not only reduce servo drive system and related energy costs, but also integrate both the programmable logic controller (PLC) and human-machine interface (HMI) functions.

Hycorr's electrical engineer, Mike Walter explains: "We have been building servo driven rotary die-cutters for over 10 years. We wanted to look at a new system for a series of machines that were being built for new customers. After the first price pass, we knew we needed to continue our talks with Siemens."


Siemens Hycorr machine control application photo 2

Servo drives control all machine functions.

The Siemens package under consideration included servo motors, Sinamics S120 servo drives, and a Simotion D motion controller with PLC functionality. "At first, we were only considering this new system for the motion platform," Walter says. "We needed a servo system that would eliminate some gears and maintain the tight tolerances our customers expected for printing and diecutting. We really needed a system with built-in rotary motion functionality."


About Hycorr Machine Corp.

Hycorr produces rotary die-cutters, flexo folder gluers and stacker systems in service to the paperboard industry, especially independent box makers of corrugated containers.

Hycorr Machine Corp. has a competitive, can-do spirit reflected in the company's many firsts: Hycorr was the first U.S. rotary die-cutter to introduce an integrated stacker, the first U.S. builder to introduce the reverse angle doctor blade on rotary die-cutters and the first builder in the world to offer an automatic cutting-anvil speed compensator, Auto-CompTM, which was later joined by Hycorr inventions of a quick-change anilox roll system and modular dwell section with inter-station dryers. All these innovations to the industry were achieved in the first 15 years of operation for this company, founded by Fred Harrison in 1985.


Siemens provided the Simotion Shaftless Drive Standard software (see box) to Hycorr. The solution reduced Hycorr's costs in both hardware and engineering time in terms of the product acquisition costs as well as the operating energy costs associated with these typically high-power-consuming machines.

Walter says he and his team determined that the Siemens motors and drives package was an ideal replacement for the previous vendor's technology; plus, the integration of the PLC and HMI afforded Hycorr additional advantages in control and operational flexibility.

In the proposed implementation of the new solution, each technology (motion, PLC and HMI) had built-in connectivity to the others, reducing assembly time (and cost) for this machine manufacturer. Overall, the savings for Hycorr was calculated to be approximately 50% when it came to the components of the system.

An added benefit was a footprint reduction of 30% in control cabinet space. As Walter puts it, "The components were smaller. With the combination of the active interface module and active line module, we eliminated the need for line reactors or line filters, thereby saving space, plus mounting and hardwiring time." The Siemens servomotors specified for comparable performance levels also were considerably smaller and less expensive to operate than the previous units used.


Building the new machine

Working under a tight deadline, the first rotary die-cutter was built and commissioned onsite by Hycorr and Siemens at the end user's plant. Shortly thereafter, the second machine, needed by another Hycorr customer, was built on a production schedule that Fred Harrison would deem another first for the company in its speed.

This improvement in engineering, production and assembly time resulted from the Simotion Shaftless Standard software, provided at no cost by Siemens to its customers. This software enabled Hycorr engineers to do much more modular implementations of components, as well use more modular interfaces for connecting the overall motion system to the controls architecture.

Using the Simotion Shaftless Standard, Hycorr saved approximately 80% of its engineering time on the machine build, says Walter. The entire engineering file for the first machine was loaded from a single compact flash drive and, with minimal debugging, the engineering on the second machine was completed quickly. This demonstrated the serial machine benefits of Simotion, says Walter.

Components used on the machine builds at Hycorr included Siemens Sinamics S120 drives, Simotion D425 motion controller,1PH7 servomotors and Simatic S7 PLC for simple Microsoft Windows based operator interface. As part of the Shaftless Standard package, Hycorr is able to make custom modifications to the various options offered on its rotary die cutters, without extensive engineering time.

Fred Harrison says, " Hycorr will continue to strive to be first on the market with many innovations, always maintaining the highest quality standards of machine performance. No customer will ever be a trial case for us. We deliver productivity to our customers' bottom line because we've invested in maximizing our own."

Siemens Hycorr machine control photo

Siemens drive motors on the die cutting end of the machine.

Siemens Hycorr machine control detail

- Edited by Renee Robbins, senior editor
Control Engineering News Desk
Machine Control, Motion Control news from Control Engineering



More on Siemens SiMotion shaftless drive standard
Kristie Simon, project engineer with DMC, an engineering and software development services firm for manufacturing, testing, and product development organizations in the Chicago area and throughout the world. In a blog post on April 01, 2010, Simon explains the Siemens SiMotion Shaftless Drive Standard:

In many industries, shaftless drive technology has replaced the old mechanical drive systems. Instead of using mechanical gearing to force one axis on a machine to follow another one, servos are used. The servo technology reduces many of the flaws of a large mechanical gearing system as well as provides a lot of flexibility.

Using the shaftless drive technology requires the use of a motion controller to command the system. Siemens Industry and Automation's motion control platform, SiMotion, ... allows the programmer to configure all of the drives and axes with great flexibility and detail, and gives the capability to program in three different languages: text-based, ladder or function block diagram (FBD), and in a motion chart.

A typical approach to programming a shaftless drive solution would be to do any math required in the text-based portion, any peripheral I/O control and basic sequence logic would be done in ladder, and all of the motion commands to control the axes/drives would be programmed in the Motion Charts. The Motion Chart section would contain all of the individual motion commands to control the axes from enabling and disabling, to moving to a position, to gearing.

Since most of the shaftless drive solutions follow the same control strategy, Siemens has created the "SiMotion Shaftless Drive Standard". This Standard outlines a programming structure and contains a library of functions that work well to control such solutions.

The basic ideas contained in this strategy are outlined below:

•is is performed through a standard mode interface.

Simon goes on to describe a printing application project, and the benefits of the Shaftless Standard.




No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2013 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...
The true cost of lubrication: Three keys to consider when evaluating oils; Plant Engineering Lubrication Guide; 11 ways to protect bearing assets; Is lubrication part of your KPIs?
Contract maintenance: 5 ways to keep things humming while keeping an eye on costs; Pneumatic systems; Energy monitoring; The sixth 'S' is safety
Transport your data: Supply chain information critical to operational excellence; High-voltage faults; Portable cooling; Safety automation isn't automatic
Case Study Database

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.

Maintaining low data center PUE; Using eco mode in UPS systems; Commissioning electrical and power systems; Exploring dc power distribution alternatives
Synchronizing industrial Ethernet networks; Selecting protocol conversion gateways; Integrating HMIs with PLCs and PACs
Why manufacturers need to see energy in a different light: Current approaches to energy management yield quick savings, but leave plant managers searching for ways of improving on those early gains.

Annual Salary Survey

Participate in the 2013 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.

2012 Salary Survey Analysis

2012 Salary Survey Results

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.