Winding and Forming Machine Control Panels for a UK OEM Machine Builder
Sector:
OEM & Special Purpose Machinery, General Manufacturing
Type:
New Build - Control System, Software, Robotics
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl designed, built, and commissioned two independent control panels — one for a winding machine and one for a forming system incorporating a robot cell — together with all associated PLC and HMI software, documentation, and site acceptance testing, for a UK OEM automation integrator.
Challenge
A UK OEM automation integrator required control panels for two distinct machine systems: a winding machine and a forming system (which also incorporated a robot cell). The two systems needed to be housed in separate enclosures and operate independently, while still being interfaced with one another.
The customer required a full turnkey scope covering electrical design, panel build, PLC and HMI software, safety performance level assessment, thermal analysis, factory acceptance testing, machine wiring, and site commissioning — with the design structured to support repeat builds of the winding machine at a reduced per-unit cost.
Solution
DelaControl produced full electrical schematics and general arrangement drawings for both the winding machine and the forming system panels, working from a customer-supplied device list and component topology. Both systems were designed as independent but interfaced enclosures, with the robot cell controls integrated into the forming system panel. All drawings were issued in native and PDF formats for customer approval prior to build.
A comprehensive documentation package was produced for each system, including a SISTEMA report to BS EN 13849-1 to establish the achieved safety performance level, thermal calculations using Rittal Therm software, a Declaration of Conformity to the Low Voltage and EMC Directives (in accordance with BS EN 60204-1, BS EN 61439-1, and BS EN 61439-2), and a signed FAT certificate following pre-delivery testing.
PLC and HMI software was developed by DelaControl for the winding machine control system. Pre-delivery testing used IO simulation test boxes and test motors to verify correct system operation prior to delivery.
Following factory acceptance, DelaControl carried out panel installation and machine wiring on site, with Site Acceptance Testing (SAT) performed by two controls engineers to verify correct operation of the complete machine. The scope was structured so that software development represented a one-off cost, with repeat winding machine builds available at a fixed per-unit price.
Key Facts
• Two separate, independently designed control panels delivered: one for a winding machine, one for a forming system
• Robot cell controls integrated within the forming system panel
• PLC and HMI software developed as part of the scope
• SISTEMA report produced to BS EN 13849-1
• Thermal calculations carried out using Rittal Therm software
• Full FAT (factory) and SAT (site) testing included in scope
• Repeat build pricing agreed for up to three additional winding machine units