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Control System Migration — Aluminum Can-Stock Cupper & Uncoiler

Automation Allen-Bradley Ball Corporation 2023

Ball Corporation's Cupper 1 and Uncoiler machines — the 24oz cup-blanking area of an aluminum beverage-can line — ran on an obsolete Modicon PLC and Parker HMI with no viable long-term support path. I migrated both to Allen-Bradley ControlLogix L81 and PanelView Plus 1000, integrated over EtherNet/IP with the line's master PLC.

Scope of Work

  • Process, network and electrical audit, plus a full review of the legacy program logic.
  • Logic migration to Studio 5000 v33.
  • New PanelView 1000 HMI application — screens, alarms, recipes.
  • Panel installation and Ethernet cabling.
  • Manual and automatic sequence testing with live product, followed by FAT.
  • Documentation and operator training.

Architecture

The Cupper 1 and Uncoiler PLCs communicate with the line's master "Line Control" PLC over EtherNet/IP. The HMI exposes motor status, main/manual drive speed, coil count and fault diagnostics (e.g. "Falla de comunicación con Line Control").

Technology

  • Allen-Bradley ControlLogix L81, PanelView Plus 1000
  • Studio 5000 v33
  • EtherNet/IP
Aluminum coil uncoiler and cupper tooling on the production line Studio 5000 Logix Designer project for the migrated Uncoiler controller