Vertical cutting device
The device is designed for cutting foam blocks into precisely specified dimensions. It is equipped with a mechanism consisting of two linearly adjustable guides, which are used to hold the material in place. The cutting is performed by a saw mounted on a sliding arm. The entire system is controlled by servomotors, which allow for positioning of the cutting unit and guides with millimeter precision, ensuring high quality and accuracy of cuts.
CUSTOMER REQUIREMENTS
- Replacement of the control system (PLC), inputs-outputs, control panel (HMI), and frequency inverters
- Complete reprogramming of the vertical cutting device
- Optimization of individual cutting modes
USED COMPONENTS
- PLC System Lenze C 430 - The c430 controller enables you to conveniently solve high-quality control tasks for coordinated movement of multiple axes with high dynamics.
- Frequency inverters Lenze i700 - The i700 cabinet servo inverter is suitable for dynamic motion control and multi-axis applications.
- HMI panel Lenze v450 - IP67 protection rating, modern and slim design, power over Ethernet (PoE) for simplified cabling
Picture 1. PLC c430
Picture 2. Inverter i700
Picture 3. HMI v450
BLOCK DIAGRAM
CONTROL CABINET AND CONTROL PANEL
During the overhaul of the distribution cabinet, the original Siemens control system was replaced with a Lenze c430 programmable logic controller (PLC). To optimize system integration and compatibility, all input-output (I/O) modules were replaced with components from Lenze. The original HMI panel was dismantled and replaced with a new Lenze HMI v450 interface, which was implemented into the control panel located on the opposite side of the machine.
As part of this modernization, the existing frequency inverters were also replaced with the new Lenze i700 series, which operate on a power bus system. This system allows the entire array to be powered by a single central power supply and protected by a single protective device, significantly simplifying the electrical wiring and reducing the number of necessary components.
For communication between the system components, a high-speed industrial communication protocol, EtherCAT, was implemented, ensuring efficient and reliable data transfer between the control unit, I/O modules, and drives.
Picture 5. HMI Control dislay
Picture 4. i700 inverter
PROGRAMING
The task involved the complete reprogramming of a saw control system using the PLC3 Designer software from Lenze. The first phase focused on activating the individual servo drives and testing basic positioning operations of the guides and saw arm. Following this, the cutting mechanism itself was activated.
Once the drives were successfully activated and the functionality of all sensors and safety elements verified, the main programming began. This phase involved developing control algorithms and synchronizing the system's components.
Four operating modes were implemented into the system: Manual, Semi-Automatic, Automatic, and Service mode. The key reason for the system reconfiguration was to optimize the functionality of these modes. The entire machine is now operated via a newly installed HMI interface.
The reconstruction resulted in significantly improved reliability and adaptability of the system, reducing cycle times and speeding up setup processes. Additionally, since the system is based on Lenze components, diagnostics and troubleshooting were simplified.
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