Outlier's Role

Outlier engineered and implemented the PLC, HMI, and motion control programming solution for a drum grooving machine.
 

TECHNOLOGIES

  • Siemens S7-1200
  • WinCC Basic HMI panel
  • SEW EURODRIVE MOVIDRIVE Servos
 

SITUATION

Our client, an established OEM with decades of experience in industrial machinery, approached us regarding their legacy drum grooving machine. Originally designed with hydraulic controls, the machine was ready for modernization, and the end-customer was requesting an updated version of the machine. The end-customer is standardized on the Siemens automation platform, so they wanted to use Siemens products in the redesign. We, at Outlier, have extensive experience working with Siemens platform, so we were brought in to help modernize the machine while maintaining the original functionality and performance.

SOLUTION

Outlier architected and programmed the machine automation which included various motion control techniques to accurately and repeatedly form the material. The programming solution utilized point-to-point motion, position-based velocity blending, and load compensation optimization. Outlier also added functionalities that enabled the machine to track life cycle performance, facilitate operator troubleshooting, and support recipes for various drum sizes. During commissioning, Outlier closely worked with the customer’s mechanical team to meet machine cycle time, material handling quality, and overall machine performance.

CASE STUDY HIGHLIGHTS

  • Outlier performed load compensation optimization to improve the accuracy and precision of the drum shape. Outlier's solution also incorporated a velocity-control algorithm which used the servo's current position to accurately and repeatably perform a critical machine operation.

  • Outlier was able to replicate the complex functionality of the original machine while improving the machine's operation and troubleshooting toolset.

  • Outlier worked with the customer's mechanical team to commission the machine at the customer's facility under a tight deadline. Outlier helped with the machine optimization to ensure that it met performance requirements.