Case Study : Press Loader/Unloader

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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A large automotive supplier had outdated inflexible controls for a hydroform press load/unload system. The outdated control components were not only unavailable, but the system was unsafe based on today's standards.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

ONYX Engineering 

3 - Controls Engineer


Services Provided

Controls 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