Scope of Work
- Migrated the SLC 500 PLC to a ControlLogix 1756-L71.
- Migrated the 10" PanelView 1000 HMI.
- Migrated 13 servo drives and servomotors (1394/1326 family) to Kinetix 6500 — the drivetrain for the machine's 8 coordinated motion axes.
- Migrated 3 additional AC induction motor drives to PowerFlex 525 (non-motion auxiliary drives on the same platform).
- Designed, fabricated and installed a new control panel, shipped from our shop to the plant.
- Commissioned within 14 days with zero reduction in production capability.
Motion Architecture
8 coordinated machine axes, implemented using 13 servo drives/motors: the line's motion functions — Unwinder, Folders/AuxPull, Main Pull (master axis), Cross-Cutter (running a non-linear electronic-cam profile), Separator, Diverter, Crossfolder 1 & 2, PlateFolders, Stackers and Collector — are synchronized off the Main Pull master axis, running up to 40 sheets per minute. (All 13 servo drives were part of the coordinated migration, but not all 13 are counted among the 8 named motion axes: some are commanded through true coordinated-motion instructions, while others are servo-driven but sequenced through standard machine ladder logic rather than motion instructions — which is why the drive count exceeds the axis count. The original delivery record states both "8-axis" and "13 servo drives" without itemizing exactly which drives fall in each category, so that precise split isn't reconstructed here — only the two headline counts are stated, each accurately, as the source documents them.)
Technology
- Allen-Bradley ControlLogix 1756-L71, Kinetix 6500, PowerFlex 525
- 1326 AB servomotors over EtherNet/IP with CIP-Motion
- Remote I/O (FlexIO) on a star/ring network topology
Deliverables
- Full electrical and mechanical diagrams
- Operating manual and troubleshooting guide
