1. Objective:
Upgrade Hauni P80 control system by installing a new PLC system based on the Beckhoff C6030-0060 Industrial PC and rewiring all key sensors and motors to improve reliability, diagnostics, and machine performance.
2. Project Background:
The Hauni P80, a high-speed cigarette packing machine, has been operating on an outdated control system with aging electrical wiring, limited diagnostics, and hard-to-source components. Over time, the machine has faced increasing issues such as wiring faults, sensor failures, inconsistent motor performance, and downtime due to limited troubleshooting capabilities.
To improve machine reliability, performance, and extend the equipment’s operational life, a full upgrade to a modern PLC system is proposed. This includes:
- Installation of a Beckhoff C6030-0060 Industrial PC, which offers a powerful and compact platform for PLC and automation control.
- Rewiring key sensors and motors.
- Replacing outdated components.
- Ensuring all connections meet current industrial standards.
The upgraded system will provide better control, faster troubleshooting, and open the door for future enhancements like HMI integration, remote monitoring, and automation expansion.
3. Key Benefits:
• Stable Operation: Fewer wiring faults, better signal response, and robust performance with Beckhoff’s industrial-grade PC.
• Improved Maintenance: Clear layout, enhanced diagnostics, and easy-to-trace wiring.
• Upgradability: Future-ready for advanced HMI systems, IoT connectivity, and automation upgrades.
• Safety Compliance: Meets modern electrical and industrial safety standards.
Installation of new drive system with rewired motor connections during P80 PLC upgrade.
1. Objectives:
Hauni P80 Conversion – Size Change from King Size to 6.35 × 89mm (30+59)
2. Project Background:
The Hauni P80 is currently configured for King Size production. Due to a new customer requirement and evolving market trends, there’s a need to switch to a slimmer and shorter cigarette format. This change will support brand diversification and capture new niche segments.
- 6.35mm diameter
- 89mm total length (30mm filter + 59mm tobacco rod)
- 120mm filter rods (4-cut for 30mm)
- 70mm tipping paper
This conversion involves significant changes to key modules, especially in rod forming, cutting, tipping, and filter processing systems.
3. Benefits:
- Product Variety: Supports new market segment with slim/short format
- Minimal Investment: Leverages existing P80 infrastructure
- Flexible Format Capability: Keeps the machine adaptable to market changes and prevents obsolescence.
- Improved Market Reach: Enables tailored product development
Final assembly zone adapted for 6.35 × 89mm configuration.
Following major tasks need to carry out for the above conversion on this maker combination:
-
- The hopper drive gear box.
- Trimmer unit complete.
- Trimmer drive gear box.
- Variable pulley
- Dense end timing setting
- Printer unit / setting.
- Printer drive gear box
- Main drive gear box
- Garniture unit
- Cut off unit complete
- Ledger crank / stroke setting
- Garniture unit / short / long / heater/ weight control setting.
- Tape drum setting
- V way / accelerator setting.
- Link up gear box.
- Fluted drum.
- Cig grading drum
- Filter hopper
- Filter cutting drum / guides.
- Filter round knife unit
- Filter grading drum
- Aligning drum/ guides/cover.
- Accelerating drum / guides.
- Swash plate drum
- Rolling drum
- Rolling block complete
- Turning drum
- Tipping bobbin
- Tipping paper guide
- Tipping spicing
- Glue roller
- Cork drum / knife
- Inspection drum
- Transfer drum
- End scanner
- Sampling device
- In feed unit
- In feed conveyor