We undertook a complete design, build, install and commission project for a domestic hot water boiler assembly system in Asia.
The system consisted of 120 individual driven conveyor sections, driven by 24VDC powered rollers on each section. There was a main highway section and 4 separate specific function spurs off the main highway, so there were common assembly actions done on the main highway section with product specific assembly sections for each of the 4 spurs. The assembly sections consisted of lift stations, tilt stations and turntables.
Our control system solution comprised of a main cabinet housing a Siemens PLC, with 4 remote I/O cabinets with remote I/O communicating via Profinet.
At each of the spur decision sections we had a Datalogic Matrix bar code reader communicating to the main PLC via Profinet I/O to give the main system information about the product type.
The system was designed to be as flexible as possible to allow for current and future products, so the operator interface facilitated options for all of the conveyor section workstations.
The operator interface was done with a Siemens TP700 HMI unit at the main control panel, there was also a Wonderware Historian system logging production information.
In total there were approximately 500 discrete I/O points, in addition to the Profinet communication interface. We also installed a system to allow remote access to the PLC and HMI system to allow us to provide rapid support.
After completion of commissioning and training the client reported that they were delighted with the boiler throughput and uptime of the new assembly system in addition to the support they received.
