Simulated Green Brick Manufacturing Machine
CSR PGH Brick Factory (Oxley
Customer: CSR PGH Brick Factory (Oxley
Duration: 4 months
Completion: Jan 2012, Jan 2013
Taking place over the annual shut down period for CSR a massive upgrade was planned to be executed by Integrelec. For this upgrade a number of old hydraulic operations were to be replaced by SEW Servo motion control drives. A transfer of machinery from another CSR site was also taking place and Integrelec had the responsibility of integrating these machines into the existing system while transferring some existing control into a new Schneider PLC whilst developing new control for the transferred machines. In addition to this two more safety zones were to be added using a number of safety devices.
Firstly a new Schneider Premium PLC was set up and installed. All new programming was to be done on this new PLC transferring over a lot of old code from the existing Modicon Legacy PLC. The Simulated Green Rumbling’s (SGR) machine is used to develop a unique pattern on each brick as they are being manufactured. This operation was previously carried out using hydraulic control. For this upgrade the control was transferred from hydraulic control to SEW servo non-contact motion control. Another aspect that was added was a new remote I/O that operated pneumatic controllers for a section of the machine. This remote I/O was installed via a network connection; Modbus TCP. As with all PLC work an operator control interface was needed and the SCADA system was also redesigned to incorporate the new machinery and control systems. With this a number of new operating modes were designed and implemented. Two new safety zones were created for the new machinery consisting of three sets of light curtains and a number of emergency-stops were programmed into the existing safety system.
In January 2013, the second stage of this project was undertaken. This involved the upgrade of the brick collation and setting machine which stacks the bricks ready for firing in the kilns. Again various old hydraulic systems were replaced with new PLC controlled servo motors. All project schedules were achieved successfully.
The key to all successful commissioning is the preparation work that is put in beforehand. With this project Integrelec worked for almost three months to get the software in the right condition that it needed to be in with such a short timeframe for commissioning. While the CSR electricians were making the necessary hook ups Integrelec was at hand to integrate the new machinery and software with existing software. Many hours of testing resulted in a smooth operation of the machinery when the plant was back running in full production.
- Non-contact motion control
- Completing work in designated shut down period
- Integration of new PLC and machinery with existing machinery and software
- Adaptability with system redesign
- Zero minutes lost due to work place injuries or accidents
- Schneider PLC Programming
- iFix HMI Design and Programming
- SEW motion control
- Installed Two New Safety Zones w/Light Curtains and E-stops
- Remote I/O through Modbus TCP
- Staff Training