Control Panel Design Contest

2010 winner of the Control Engineering Control Panel Design Contest is... Specialty Tooling Inc., Evansville, IN. View the finalists, learn more about the winner, and link to information about submitting a video for the 2011 Control Panel Design contest.

04/15/2010


Control Panel Design Contest

 

 

 

Watch the Control Engineering 2010 Control Panel Design Contest winner, a tutorial video from Specialty Tooling.

Scroll down to watch the Control Engineering 2010 Control Panel Design Contest winner, a tutorial video from Specialty Tooling, of Evansville, IN.

Link to information about submitting a video for the 2011 Control Panel Design Contest.

Ryan Johann, automation engineer, Specialty Tooling says panel design considerations include power consideration, isolation, drives, controls, communications, and layout for appropriate placement with minimum wiring.

Ryan Johann, automation engineer, Specialty Tooling says panel design considerations include power consideration, isolation, drives, controls, communications, and layout for appropriate placement with minimum wiring.

The end-user is a major appliance manufacturer. The application is a machine that applies bends and twists to the tubing on the bottom of a refrigerator. The controls challenge was to reduce wiring, cabinet space and eliminate the 90-minute hard tooling change-over. Among four finalists that submitted tutorial videos on control panel design in 2010, subscribers voted online to select machine builder Specialty Tooling's tutorial video as the winner.

Ryan Johann, automation engineer, explains: "When I'm laying out control enclosures, my thought process is,‘Where is it going to be easiest to bring my I/O cabling in from the machine, what kind of components do I need to have with 480 V ac, 3 phase, or 24 V dc? What's the supply power? What kind of drives, controls, and communication cables do I need? And how can I think about how to isolate the highand low voltage, to keep noise out of the equation."

Specialty Tooling control panel design saved about 25% on panel size, decreased wiring by 35%, and improved productivity by 15% by integrating safety.

Specialty Tooling control panel design saved about 25% on panel size, decreased wiring by 35%, and improved productivity by 15% by integrating safety.

The control cabinet needs to be laid out to ensure everything is placed appropriately.

Enabling tools included Bosch Rexroth's MLD-M control architecture. For the 4-axes application, Johann sought to reduce panel size. One master axis, with integrated PLC and motion control functionality, reduces the need for an external PLC that would take more panel space. The drives save space, wiring together with one wire, in a daisy chain, to SERCOS III I/O blocks.

Panel design and component selection helped Specialty Tooling resolve related controls challenges.

Panel design and component selection helped Specialty Tooling resolve related controls challenges.

Another space saving technique is having one point to terminate up to a three-wire sensor thus reducing the amount of wiring and time needed to assemble the panel.

A more traditional architecture would have required additional wiring to an external PLC or motion controller with I/O cards back to a separate portion of the panel. The Specialty Tooling control panel design saved about 25% on panel size, decreased wiring by 35%, and improved productivity by 15% by integrating Bosch Rexroth's Safety-On-Board technology. Ordinarily the operator would need to drop the 480 V ac power to the drives in the work cell to load and unload the part. MLD Safety on Board technology meets safety requirements by putting the drives into a safe stop condition when the operator is in the work cell, Johann says.

Software tools, such as these from Bosch Rexroth, help with control panel design, programming, and automation system integration, Specialty Tooling says.

Software tools, such as these from Bosch Rexroth, help with control panel design, programming, and automation system integration, Specialty Tooling says.

Software from Bosch Rexroth helped Specialty Tooling program, integrate, and execute all project components, including PLC and motion programming, human-machine interfaces, and I/O connections.

Good tools help a smart design.

Thanks to all participants and voters, and 2010 contest sponsor, Phoenix Contact. Scroll down to link to videos and more information. Leave your comments or advice online.
Also contact:
Specialty Tooling 812.464.8521
www.boschrexroth.com
www.sercos.com
www.solahd.com

Video finalists for 2010 are available for viewing, below.

Submit a tutorial video for 2011 here:

http://www.controleng.com/events-and-awards/control-panel-contest.html


Advertisement
Phoenix Contact sponsors 2010 Control Engineering Control Panel Design Contest


cpv_ats_systems_150

ATS Systems Oregon

Flash suppression panel and

power distribution

 
Watch Here -2010 finalist
CPV Concept Systems

Panel Design by Concept Systems

Teamwork is key to compete and exceed
our customers' expectations

 
cpv_premiere_automation150

Premier Automation

The Art of Panel Building

at Premier Automation

 
Watch Here - 2010 finalist
cpv specialty tooling 150

Specialty Tooling Inc.

With integrated motion, logic, control and Safety-On-Board drive technology, Specialty Tooling's control cabinet design is 25% smaller with 35% less wiring costs and 15% higher machine productivity.

 
Watch Here - 2010 winner

 



The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Robotic integration and cloud connections; SCADA and cybersecurity; Motor efficiency standards; Open- and closed-loop control; Augmented reality
Controller programming; Safety networks; Enclosure design; Power quality; Safety integrity levels; Increasing process efficiency
Additive manufacturing benefits; HMI and sensor tips; System integrator advice; Innovations from the industry
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
This article collection contains several articles on how automation and controls are helping human-machine interface (HMI) hardware and software advance.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Automation Engineer; Wood Group
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me