Seamless dc to ac drives retrofit

Pliant Corp is a producer of value-added films and flexible packaging products. Engineers at its Macedon N.Y. plant asked Omron IDM Controls (Houston, Tex.) to retrofit the drives on one of the plant's older six-color flexographic printing presses. Pliant uses the older press to develop new printed substrates made from different poly film constructions of varying thicknesses.

03/01/2002


Pliant Corp is a producer of value-added films and flexible packaging products. Engineers at its Macedon N.Y. plant asked Omron IDM Controls (Houston, Tex.) to retrofit the drives on one of the plant's older six-color flexographic printing presses. Pliant uses the older press to develop new printed substrates made from different poly film constructions of varying thicknesses.

The existing dc drive system was unable to maintain tight control of web tension after each material change, which is the precision needed to produce high-performance, cost-effective packaging. Quality had to be maintained at minimal cost, so Pliant chose to retrofit the existing machine with ac drives rather than purchase a new press.

Design plans called for installation of an ac drive system at each of nine machine sections in which Pliant engineering installed high-performance Omron IDM G5 Series ac vector drives. Each drive is connected via a Profibus network to an existing Allen-Bradley SLC-5/04 PLC. An additional I/O chassis was included to accommodate the drive system.

Because the engineering team was working with existing automation hardware, software, and infrastructure, several integration challenges arose. Since the ac drives came with a Profibus interface, a Profibus-DP Master Card from SST (Waterloo, Ontario) had to be integrated with the Allen-Bradley PLC for communications to the drives. While this is not a difficult task from a programming standpoint, coordinating the Allen-Bradley PLC, Profibus DP Master Card, and Profibus parameters within the drives to work together in a seamless, efficient manner was labor intensive.

Reconfiguring the system

In the new configuration, Pliant's engineers integrated the drive control logic into the existing PLC program, redirected the old I/O points into the new logic, and connected the new drives over the network, greatly simplifying the wiring scheme and increasing network efficiency. In addition, tight clearances required that all new hardware and wiring be incorporated into existing cabinet space.

The technology applied in this system is most evident on the rewind end of the machine. As the printed film rewinds onto the spindle, the roll must turn slower as it increases in diameter to maintain the same surface speed as the line. The new winder control software calculates the diameter and regulates tension during this process. This function is critical to the quality of the final product. The ac drive's CASE (Custom Application Software Environment) capability was used to perform this function internal to the drive, thus saving implementation time and costs that Omron IDM Controls was able to pass along to Pliant. Additional time, money, and space savings were achieved using a common dc bus system to power the drives. This configuration uses a single dc power supply and a braking unit for all the drives, reducing the parts count and system wiring, and allowing the drives to share power. Benefits of the retrofit include a dramatic reduction in press downtime and a decrease in scrap due to precise web tensioning.

For more information on Omron IDM Controls, visit www.controleng.com/freeinfo .


Author Information
Richard Lewis is a design engineer for Omron IDM Controls Inc., Houston, Tex.




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.
Women in engineering; Engineering Leaders Under 40; PID benefits and drawbacks; Ladder logic; Cloud computing
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
This article collection contains several articles on how advancements in vision system designs, computing power, algorithms, optics, and communications are making machine vision more cost effective than ever before.
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 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.
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.
Women in engineering; Engineering Leaders Under 40; PID benefits and drawbacks; Ladder logic; Cloud computing
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
This article collection contains several articles on how advancements in vision system designs, computing power, algorithms, optics, and communications are making machine vision more cost effective than ever before.
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 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.
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.
Women in engineering; Engineering Leaders Under 40; PID benefits and drawbacks; Ladder logic; Cloud computing
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
This article collection contains several articles on how advancements in vision system designs, computing power, algorithms, optics, and communications are making machine vision more cost effective than ever before.
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 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