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Thermoformer and Trim Press Control System Upgrade

Overview:

BCS Motion was recently approached by a major plastic cup manufacturer looking to replace an obsolete servo control system with a new, state-of-the-art motion control system, complete with machine controllers and a new operator interface, to aid in production. The company’s original system was proprietary, outdated, and contained little documentation.

BCS Motion assessed the client’s needs, and delivered a new, updated thermoformer and trim press control system to the plastic cup manufacturer.

Solution:

After assessing the unique needs of the client, BCS Motion developed a completely new control system for the Thermoformer, which included heaters, machine controllers, and a new operator interface. Engineers at BCS upgraded the existing trim press controls to communicate with the Thermoformer. Communications between the Thermoformer panels and the Trim Press panel were accomplished via ModbusTCP and Mechatrolink deterministic digital network.

BCS Motion developed the HMI to mimic operator functions found on the manufacturer’s other machines, thus reducing the learning curve for set up and operation personnel. To reduce the foot print of the machine on the factory floor, BCS Motion suggested mounting the new control panels back to back.

This automation control solution included four Yaskawa Sigma 5 motors and drives, a Yaskawa MP2300Siec machine controller, and a Proface industrial PC. These components were uniquely chosen by application engineers at BCS Motion to provide the most effective and reliable solution to the clients individual automation challenges.

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Challenge

Replace an undocumented, proprietary, and obsolete motion control system with a new, state-of-the-art servo control system, machine controllers, and operator interface that mimicked existing operator functionality of other machines.

Results

ZERO

 Field service requests since system implementation.

“BCS Motion’s expertise in motion control solutions is unmatched. They were able to replace our outdated system with a state-of-the-art machine, while providing us with a solution that made our transition from machine to machine seamless.”