Client Goal

Business & Technical Goals

• Increase line production and efficiency
• Eliminate product delivery delays
• Integrate system with existing line under a very aggressive startup timeline
• Provide system modifications with minimal existing production impact
• Deliver within rapidly changing design requirements
• Improve overall line Motion Control Strategies
• Develop phase adjustment capabilities based on registration events
• Develop the motion equations and conceptualize the hierarchy of control prior to an implementation in the controller
• Integrate 12 axes of motion in a control hierarchy with a master axis fed from the preserved upstream equipment
• Create an electronic camming algorithm to allow for constant velocity control at certain points in the profile.
• Develop multiple contingency scenarios to allow for flexibility during startup
• Develop modular programming design to allow for reuse and adaptability in the field.

Project Overview

The project included full electrical / control system hardware design, PLC programming, HMI development, and system commissioning.  All mechanical design and fabrication aspects of the project were done by the client.

Facing an imminent backorder situation, the client looked to Tegron to deliver a complete automation solution with an unproven, technically complex process. The new process would replace 50% of an existing automation line, making the startup timeline extremely aggressive. 

Tegron worked closely with the client’s internal project management and mechanical design resources. Adaptability was key. The servo motors were chosen for all axes to allow for the greatest flexibility in the field, as it was not possible to test production-level feed rates prior to integration into the existing process. This proved to be a solid design decision as a  major change in one of the process areas was required during startup regarding production level feed rates yielding startup conditions previously not defined.  The flexibility provided by our modular object oriented approach to the software and electrical design proved extremely valuable at startup.

Scope of Supply

Full electrical control system hardware design, PLC programming, HMI development, and system commissioning.

The Outcome

Close cooperation between Tegron and the client allowed for a successful delivery with a very aggressive timeline. Our development of a flexible, well-thought-out design strategy, along with contingency plans, made the project a success.

The net result was a 20% increase in productivity, eliminating the risk of backorder and allowing the client to continue, uninterrupted, service their customers. Tegron received recognition from the client as an outstanding supplier that converted a difficult challenge into a successful solution.