Large Hand Curler Control System for a UK Tolerance Ring Manufacturer
Sector:
General Manufacturing
Type:
New Build - Control System, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl designed, built, and commissioned a complete control system for a large hand curler machine at a UK tolerance ring manufacturing site. The scope covered a Siemens S7-1212FC safety CPU with ET 200SP remote I/O, a Sinamics S210 servo drive, a 10-inch Unified HMI panel, PLC and HMI software, a full documentation pack, factory acceptance testing, site installation, and commissioning.
Challenge
A UK tolerance ring manufacturing company required a new control system for a large hand curler machine, built to a User Requirement Specification. The system needed to support motion control, a significant safety I/O count, and operator interface via an HMI, with at least 20% spare capacity built in across I/O, backplate space, and power distribution.
The customer's specification called for a specific version of Siemens TIA Portal, and required the control system to be delivered with full documentation including electrical schematics, safety engineering outputs, thermal calculations, an HMI operating manual, a spares list, and a factory acceptance test.
Solution
DelaControl selected a Siemens S7-1212FC failsafe CPU paired with a Siemens ET 200SP distributed I/O system to meet the machine's standard and safety I/O requirements. A Sinamics S210 servo drive was included for motion control. The control panel was housed in a Schneider PanelSeT wall-mount enclosure, with a separate HMI enclosure carrying a 10.1-inch Siemens Unified Basic Panel. A SITOP power supply with selectivity module was used for 24 V DC distribution, and an ABB 4-pole isolator provided the main incoming isolation.
PLC and HMI software was developed by DelaControl to the machine's operational description, using TIA Portal V20. A SISTEMA report was produced to substantiate the PLr rating of the safety functions, and a full documentation pack was delivered including electrical schematics (AutoCAD Electrical or Eplan), general arrangement drawings, Declaration of Conformity, inspection and test schedule, thermal calculations, HMI operating manual, and a categorised spares list.
Pre-delivery testing was carried out at DelaControl's Bristol facility using I/O simulation and test motors, followed by a factory acceptance test to which the customer was invited. DelaControl then provided two industrial electricians for three days of site installation and one controls engineer for four days of site commissioning.
Key Facts
• Siemens S7-1212FC failsafe CPU (200 KB program / 500 KB data memory)
• ET 200SP distributed I/O: 8 standard DI, 8 standard DO (across 2+2 modules), 24 safety DI (3 × F-DI 8x24V DC HF), 16 safety DO (2 × F-DQ 8x24VDC/0.5A PP HF)
• Sinamics S210 servo drive, 2 kW, 3AC 200–480 V
• 10.1-inch Siemens SIMATIC HMI Unified Basic Panel (1280 × 800 TFT)
• Wall-mount Schneider PanelSeT enclosure (1000 × 600 × 300 mm, IP66, IK10) plus separate HMI consolet enclosure
• SITOP Smart 10 A / 24 V DC power supply with selectivity module
• 8-port Siemens unmanaged Ethernet switch
• Full documentation pack including SISTEMA report, Declaration of Conformity, thermal calculations, FAT schedule and certificate, HMI operating manual, and spares list
• Site installation (2 electricians, 3 days) and commissioning (1 engineer, 4 days) included in scope