Line Automation Made Easier

Installing an automated press line, or adding components to an existing line, is a complicated process. When it works just right, performance can be top-notch, yielding a high return on investment. But when it doesn’t…

Often, the success or failure of the entire process, can be tied to component capability. Getting components to act seamlessly together enables the stamper to productively churn out quality parts by monitoring and regulating all aspects of line function. To gain a better understanding of how proper design and implementation can affect line performance, MetalForming picked the brain of John Eby, product manager and applications engineer for Toledo Integrated Systems, Holland, OH, a designer and manufacturer of press-automation controls.

Simplify the Communication Protocol

Opting for a single communication protocol, according to Eby, goes a long way toward ensuring optimal press-line performance.

“Select control hardware that uses a single communication protocol (Ethernet, etc.),” he advises. “In doing this, metalformers will benefit by simplifying line communications and simplifying maintenance.”

Too often, according to Eby, control communication does not receive the proper scrutiny when specifying a line and line components.

“Many times, metalformers look to add a press, feeder or transfer system, and aren’t aware of the details surrounding the controls,” he says. “They’ll see that Allen-Bradley or Siemens processors have been specified, and assume that the components can talk seamlessly, but that is not the case. Even if processors come from the same company, different models communicate a bit differently.”

In an ideal world, reasons Eby, all control processors would be identical so that only one specific processor could be stocked to service all of the line hardware and equipment.

“But,” he says, “if X plc is selected for this, and Y for that, stocking and servicing can become a nightmare. It affects maintenance and even staffing levels. It seems that everyone I talk to is looking for a good controls engineer or technician, and one reason is the need to support so many types of control components. The less to support, the better…try to reduce the amount of different software packages and communication protocols that plant control engineers must be familiar with.”

Besides the basic communication and stocking issues, a single communication protocol with identical control components offers other benefits.

“Talking in a single network and accessing and diagnosing all of the equipment in the line without having to plug into different controls using different protocols will greatly ease troubleshooting,” Eby says.

“In addition,” he continues, “with a line set up on a single Ethernet network, for example, all line components and their controls can be accessed for remote troubleshooting.”

A single protocol with compatible control processors eases the integration process, Eby adds, as many signals can be shared and will, therefore, not require individual hard-wiring, a complicated, costly and time-consuming process.

On top of that, Eby says, with a single communication protocol, less is more.

“For example,” he says, “If I can use a single human-machine interface (HMI) to communicate to a couple pieces of equipment and have an organized, well-thought-out screen layout, I can call up needed information and troubleshoot more easily and more quickly. Common components and a single control system enable that, rather than running all over the line trying to figure out what screen to look at.”