Case Study: Press Loader/Unloader

 

REPLACE PRESS LOADER/UNLOADER GANTRY FOR SAFER AND MORE FLEXIBLE OPERATIONS

 

A large automotive supplier had outdated inflexible controls for a hydroform press load/unload system.  The outdated control components were not only unavailable, but the system was unsafe based on today’s standards. Onyx was called on to replace the existing controls to accommodate a new product that was unable to run with the existing systems as well as improve cycle time and decrease setup time. 



 







The Problem

Older controls or equipment did not provide flexibility to run the new model year product. Other issues were unsatisfactory load/unload cycle times as well as the ability to enter the cell for part setup based on today’s safety standards.

 

The Solution

Onyx Engineering designed, built and installed a new dynamic motion control system that allowed for infinite flexibility in setting up the new products.  The new system cycle times were improved by allowing concurrent load and unload through coordinated motion of all 4 motion axis.  It also utilized safe speed in conjunction with a safety motion enabling device so that operators could enter the cell and operate the machine to clear obstructions and setup jobs.


The Results

The Control System upgrade increased the usability, efficiency and safety of the existing equipment. We provided a controls system that integrated with their existing platforms and equipment and also increased visibility and decreased the operational footprint of the equipment.

Project Details


 

            ROI                            

About 12 Months

                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                 

 

          Team                        

                    Client: 1                                                      

Onyx: 3 Engineers

                                                                                                                                                                                                                                              


 

Services Provided

Control Engineering and Design

PLC/HMI Programming

Servo Motion Programming

AutoCAD Documentation  

 Start-up and Commissioning

                                                                                                                                                         


 

Technology
Used

Allen-Bradley GuardLogix PLC               

Allen-Bradley VersaView

EtherNet/IP

Rockwell FactoryTalk View SE

Yaskawa SigmaWin