Eaton Glass Collar Machine Automation
Eaton provides power management technologies and services to help their clients effectively and sustainably manage electrical, hydraulic, and mechanical power. An upgrade was needed on a continuous production line machine.
Unique Project Features
The upgrade was planned to reduce shutdown to the shortest time possible. Encorus personnel worked double shifts to reduce shutdown time.
Encorus Group Solution
Encorus Group performed a full process, PLC, pneumatics, drives and HMI upgrade on a continuous production line machine spraying coatings on small parts. An Allen-Bradley SLC controller was replaced with a modern CompactLogix, and several servo drives were upgraded to the latest Allen-Bradley drives. Encorus personnel performed reverse-engineering on the entire system, including mechanical, pneumatic, electrical and spray systems, then reprogrammed the new PLC for improved operations and functionality with the new drives. New network connected pneumatic valves and servo drives were installed, tested and commissioned. Encorus designed and implemented a segmented network using a Network Address Translation (NAT) router. The entire system was connected into a plant-wide ethernet network for reporting, alarming, programming, and remote troubleshooting. The machine throughput was increased by 25% and downtime was reduced by 90%.
Specific Project Tasks
- Develop and install HMI screens
- Replacement of Allen-Bradley SLC controller with modern CompactLogix
- Drive upgrades
- Reprogramming of PLC
- Installation, testing, and commission of system
- Design and implementation of segmented network
- Connection to plant-wide ethernet network