Replacing the factory control system (made in China) because of its lack of functionality, unreliability and complexity for understanding (characters, without translation into Russian or English).
Development and implementation of a new process control system for an expensive machine.
The machine is designed for the manufacture of wire products according to the following algorithm: stepper motor unwinds the necessary length of the wire, then the wire is made into a required form using 10 hydraulic cylinders. Depending on the complexity of the products, the machine allows to produce more than 2500 products in 8-hour shift.
The control system was based on PLC and operator panel by Xinje (Thinget) (controller XC3, OP330 operator panel) and a stepper motor Leadshine 3ND2283. PLC program was developed in XCPPRO environment. Panel program – in OP20 Editor.
The machine worked for a long time, but after the failure of the battery, the controller did not have a password, which factory-manufacturer could not provide for various reasons. As a result, the control system was locked and stopped working altogether. It was decided to rewrite the control program for the controller and the operator panel.
As a result, it was possible not only to recover the equipment operation, but also to make a number of important improvements.
The operator interface on the control panel is now in Russian;
The length of the wire was unwound in some arbitrary units, but after the software was replaced, the operator received an opportunity to enter the preform length in mm with accuracy up to 0.1mm;
The machine has become more versatile, since several useful parameters were added.
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