Automated OpticLine Control System: Multi-Panel Design, Build & Commissioning for a Special Purpose Machine OEM
Sector:
Aerospace & Defence
Type:
New Build - Machine, Software, Robotics, New Build - Control System
Platform:
Siemens, ABB
Certification:
CE / UKCA
Summary
DelaControl designed, built, programmed and commissioned the full electrical control system for a two-station automated OpticLine machine for a special purpose machine OEM. The scope covered two control panels, PLC and HMI software, ABB robot programming, Festo pneumatic manifold integration, full safety documentation including BS EN ISO 12100 risk assessment and BS EN 13849-1 SISTEMA report, Factory Acceptance Testing, mechanical cell build and on-site commissioning.
Challenge
A special purpose machine OEM required a complete electrical control system for a new two-station automated OpticLine machine. The customer needed an engineering partner to design and manufacture control panels for both stations from scratch, working from an IO schedule without a formal electrical specification, and to take full ownership of the build documentation and compliance pack.
The scope also required integration of an ABB robot — including robot programming, safe working zone definition, and the interface between the robot and the PLC — as well as control of a pneumatic manifold via a Festo Profinet bus coupler. The customer required the complete machine cell to be mechanically assembled and commissioned on site.
Solution
DelaControl designed and built two control panels for the machine: the primary station panel built around a Siemens S7-1200 series CPU with safety-rated I/O modules (Siemens SM 1226 F-DI and F-DQ), a Siemens TP700 Comfort HMI, and a Siemens Scalance unmanaged industrial Ethernet switch. Digital outputs to field devices were routed via solid state relays, and a Red Lion Crimson bus converter was included to support Ethernet device communications. All panel hardware, enclosures, circuit protection, contactors, and cabling were supplied and assembled by DelaControl at their Bristol facility.
Alongside the panel hardware, DelaControl developed the full PLC and HMI software, programmed the interface between the PLC and an ABB robot, and programmed the robot motion sequences to meet the system requirements defined by the control philosophy. Safe working zone programming for the ABB robot was also included within scope. The Festo Profinet bus coupler controlling the pneumatic manifold header was configured and integrated as part of the same software programme.
A comprehensive documentation and compliance pack was produced, including EPlan electrical schematics, AutoCAD general arrangement drawings, a Declaration of Conformity to the Low Voltage and EMC Directives, a Factory Acceptance Test schedule and signed certificate, a BS EN ISO 12100 machinery risk assessment, and a BS EN 13849-1 SISTEMA report confirming the functional safety performance level achieved by the system.
Following successful FAT at DelaControl's facility, the team carried out the full mechanical build and assembly of the machine cell and completed on-site commissioning.
Key Facts
• Two control panels designed and built — one primary station, one secondary station
• Siemens S7-1200 series PLC platform with safety-rated I/O (SM 1226 F-DI SIL2/3 and SM 1226 F-DQ SIL3) modules
• Siemens TP700 Comfort 7" touchscreen HMI
• Siemens Scalance XB008 unmanaged industrial Ethernet switch included
• ABB robot programmed including motion sequences, PLC interface and safe working zone definition
• Festo Profinet bus coupler used to control pneumatic manifold header
• Red Lion Crimson bus converter included for Ethernet device communications
• Full compliance documentation: BS EN ISO 12100 risk assessment, BS EN 13849-1 SISTEMA report, Declaration of Conformity, FAT schedule and certificate
• Full mechanical cell build, assembly and on-site commissioning by DelaControl