1. Objective
Upgrade Fresh Seal (Reloc) control system by installing a new HCFA M Series PLC controller and integrating an Autonics 3600p 24VDC encoder to enhance motion control precision, diagnostics, and overall machine performance.
2. Project Background
The Fresh Seal (Reloc), a critical system in the production line, currently operates on an outdated control platform that limits its flexibility, precision, and diagnostic capabilities. Increasing operational demands and aging hardware have led to reduced efficiency, inconsistent motion synchronization, and challenges in troubleshooting.
To ensure smoother operation, higher accuracy, and extend the machine’s operational lifespan, a comprehensive upgrade is proposed. This includes:
- HCFA M Series controller, offering advanced motion control and communication features.
- Integration of an Autonics encoder (3600p, 24VDC) for precise position feedback.
- Custom Control Functions: Tailored controls with seamless hardware integration.
- Upgrade from offset-based foil length calculation to sensor marking detection, enabling real-time calculation of foil length for improved precision and reduced wastage.
The upgraded system will improve motion coordination, simplify maintenance, and provide a foundation for future enhancements.
3. Key Benefits
• Precise Motion Control: Higher accuracy and synchronization via encoder and CAM.
• Improved Maintenance: Streamlined diagnostics and clear parameter visibility.
• Reduced Foil Wastage: Optimized alignment system reduces foil consumption, enhancing process accuracy and savings.
• Upgradability: Scalable system for future automation and communication enhancements.
• Operator Friendly: Simplified control with improved HMI interface and flexible parameter adjustments.
• Reliable Performance: High-speed communication via EtherCAT ensures smooth and consistent machine operation.
