Control System Design and Build for Can Manufacturing Line Equipment
Sector:
Packaging
Type:
New Build - Control System, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl designed and built three control systems for a set of can manufacturing line machines — a washer with integrated tornado, a pin oven, and an internal bake oven — delivering a fully tested, documented package ready for factory acceptance and deployment.
Challenge
A machinery OEM required control systems for three distinct machines on a new can manufacturing line: a washer with integrated tornado unit, a pin oven, and an internal bake oven.
The washer presented a more complex integration requirement, with a large number of variable speed drives and the need to incorporate IO-Link field sensor connectivity alongside the main control architecture.
Solution
DelaControl designed and built three separate control systems — one per machine — procuring all panel hardware, junction boxes, emergency stop stations, local motor isolators, and pin chain rotary encoders within scope. The washer control system was the largest of the three, housing 53 Siemens G120 variable speed drives across a range of power ratings and incorporating an IFM IO-Link network for field sensor connectivity, with associated M12 field cabling. The oven control systems followed established designs and were built to the same standard.
For each panel, DelaControl produced a full electrical drawing pack including schematics, general arrangement drawings, and cable schedules, together with a SISTEMA report (ISO 13849-1 assessment), Declaration of Conformity to the Low Voltage and EMC Directives, and a signed Inspection and Test Certificate.
PLC and HMI software was developed and loaded for all three machines, with panel communications configured and verified prior to dispatch. Prior to delivery, a thorough factory acceptance test was carried out using purpose-built IO simulation test boxes, with the customer invited to witness testing in person or via video conference.
Key Facts
Three control systems delivered: washer with integrated tornado, pin oven, and internal bake oven
53 Siemens G120 PM240-2 variable speed drives across the washer control system, ranging from 0.37 kW to 22 kW
8 Siemens G120 variable speed drives in the internal bake oven; 3 in the pin oven
IFM IO-Link network integrated into the washer, including 37 IO-Link masters and extensive M12 field cabling
Siemens TP1200 Comfort HMI panels on the IBO and pin oven; TP1500 Comfort panel on the washer
SISTEMA report (ISO 13849-1) produced for each machine
Factory acceptance test conducted with IO simulation test boxes; customer invited to witness