Category Archives: Case Studies

Sustainable and Eco-Friendly Drive Technology from Optima

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The innovative sinamics G220 variable frequency drive from Siemens not only helps reduce harmonics (Gary Wilcock) but is also a more sustainable drive choice. Let us explain.

The animation below shows the draft panel layouts for 8 drives using the G120 drives along with the required input and output reactors due to the long cable lengths involved for this installation. 

Shown on the right of the animation is the draft layout using the new G220 drives.

The new G220 drives, allow us to accommodate double the number of drives in one cabinet as no chokes are required.

SINAMICS G220 – the variable frequency drive for all industries

It has helped Optima Control Solutions Ltd make this a more sustainable design. 

Not only have we have reduced CO2 emissions in transit as the cabinet is lighter, we have also reduced the amount of minerals required to build by avoiding additional copper in the line chokes and steel in the chokes and cabinets.

The fusing for the other 8 drives has been moved to an adjacent cabinet where there are other drive sizes located. The control panel build is now underway. 

A big thanks to Ben Poole, too for his timely demonstration of these excellent drives. Sustainability CleanTech

 

Continued Upgrade of Batch Plant

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Batch Upgrade

When our customer needed to upgrade their aging batch processing and bulk delivery systems on site, they turned to Optima Control Solutions.

Optima were tasked with migrating the legacy control system over to  a modern integrated batch control solution with no disruption to production

APPROACH

A Rockwell Automation solution was installed, which included

  • ControlLogix PLC upgrades in each mixer / bulk system
  • Redundant Server running FactoryTalk ® Batch
  • EtherNet/IP device-level ring network topology

RESULTS

  • Reduced obsolescence risk and downtime
  • Site-wide familiarity of operator interfaces for each process
  • Ability to develop recipes away from the factory floor or off-site for ease of deployment and remote support for timely intervention in the event of any equipment malfunction
  • Reduced batching errors caused by operators

Becuase the system runs from a central batch server, the customer has the ability to develop recipes away from the factory floor or off-site for ease of deployment,. This reduces batching errors that may be caused by operators

SINAMICS G Smart Access Module

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SINAMICS Smart Access Module
Sinamics G120 Series Drive

With the SINAMICS Smart Access Module, you connect wirelessly your mobile devices (smartphone, tablet, laptop) via WiFi to the SINAMICS Gconverter series. This gives you a powerful tool with numerous functionsfor wireless commissioning, diagnostics, and service. 

The module is set up in just a few steps. No installation or downloading of additional software required due to the web server function. 

A standard web browser and a commercially available operating system are all you need. The user interface of the SINAMICS Smart Access Module is simple and intuitive in its configuration and use. Read more here:

SINAMICS G Smart Access Module

All images (c) Siemens Automation

Optima are an approved Siemens Drive Systems Integrator with a 30 year track record of delivering results on complex automation applications

Efficient Motion Control ATEX Coating

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The upgrade has resulted in the Coating Line being significantly more efficient and notably easier to operate

A coating machine installed in 1988 was facing increasing reliability and operational challenges due to its age. Key issues included:

  • Unpredictable Start-ups: The machine suffered from erratic start-ups, impacting the consistency of production
  • Frequent Recalibrations: Maintenance required regular recalibration of controls to maintain system reliability
  • Obsolete Motor Components: The DC ATEX-certified motors were no longer available on the market, and existing units were becoming increasingly unserviceable.
  • High Energy Losses in Transmission: High energy losses occurred due to inefficient PIV transmissions and aging gearboxes
Coating Machine Drive and Motion Upgrade

Solution: 

The customer needed a comprehensive solution to address the following:

  • Motor Obsolescence: Replace outdated motors to improve operational reliability and reduce unpredictable start-ups.
  • Improved Product Quality: Frequent poor coating quality, wrap-ups, and web breaks needed to be minimized.
  • Flexibility in Production: The upgraded system should be versatile enough to accommodate various products without requiring extensive reconfiguration.
  • Full PROFISAFE Integration: The machine was eqipped with a full PROFISAFE solution that incorporated safe speed monitoring. This improved operational safety and reducing risks during maintenance and production changes.
Siemens Sinamics S120 Drives in a Coating Application

Benefits: Following the upgrade, the machine achieved several substantial improvements, making it one of the most energy-efficient unit in the factory, even outperforming newer equipment. 

 
Key benefits included:
 
  1. Enhanced Energy Efficiency: The new servo motors and optimized drive system minimized energy waste, eliminating the need for ventilation or purging, which reduced fan energy consumption.
  2. Increased Production Speed: The upgraded machine operates at a higher production speed without compromising product quality, resulting in improved throughput.
  3. Reduced Mainternance Requirements: The new configuration eliminated the need for regular recalibration, easing the workload on maintenance staff.
  4. Improved Operator Satisfaction: Operators appreciated the simplified “one-touch” start functionality, which made operation straightforward and reduced the likelihood of errors.
  5. Minimized Product Losses: By eliminating web breaks and improving coating consistency, the machine reduced material waste and product rework.
This comprehensive machine upgrade resulted in a safer, more energy-efficient, and flexible production process, meeting the customer’s needs for reliability, flexibility, and operational efficiency. With improved equipment uptime, increased production speed, and lower energy costs, the customer has a future-proofed machine that supports long-term productivity and cost savings.
 
Optima are now in place to provide ongoing support and uprgades using our Remote Access system
 
Optima are an approved Siemens Drive Systems Integrator with a 30 year track record of delivering results on complex automation applications

Full Project Turnkey Solutions

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We are pleased to offer turnkey solutions to our clients. Depending upon the client’s brief and the project scope we very often manage the full project, including mechanical engineering and electrical installation. We have select sub-contract companies with whom we work regularly. Alternatively, we will readily work with customer-nominated third parties.

Our project management skills and application experience are valuable assets in this discipline.

On any project the facilities that Optima Control Solutions Ltd. provide are:

  •   Produce a detailed line control specification document
  •   Produce high quality CAD drawings
  •   Manufacture and functionally test your control cubicles.
  •   Ship the cubicles to your site
  •   Installation of the control cubicles (optional)
  •   Commissioning of the line control system
  •   Issue a fully documented User Manual
  •   Maintain a record of your drawings
  •   Provide an expert support service
  •   Equipment Installation.

Need more information? Browse various projects here. Our industry-specific pages also provide details about the control system projects we have completed over the years.

Safety Scanner Issues and EN999

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Optima were recently asked to advise on a safety guarding application for one of our customers. 

There had been a number of false trips of the laser scanner causing the machine to stop. A plastic chain ‘barrier’ had been fitted as a temporary measure with instructions to operators to not breach the barrier whilst the machine was running. 

The customer naturally wanted this rectifying as soon as possible. Optima carried out a service visit to site.

On the site visit, our engineer noted that the scanner was showing a code which indicated that the front screen required cleaning.

 Once the screen was cleaned thoroughly the scanner did not show any faults or errors and was in normal run mode.

 

Further checks on the original software were made to ensure the scanner configuration met the requirements of the safety guarding application. 

The diagrams to the left show the Warning Field configuration (Yellow) and the Protective Field (Red). Both of these were confirmed to be operational. 

The warning field causes the klaxon to operate but does nto stop the machine. The protective field causes an emergency stop of the machine.

We did find some concerns that needed addressing.

1. None of the scanner safety circuit had been documented on any drawings.

2. Non-compliance with EN999 ‘Safety of machinery. This defines the positioning of protective equipment in respect of approach speeds of parts of the human body’. It includes a formula to be used to calculate the distance from a hazard that a safety zone must be triggered. 

Based on the stopping times of the machine, the scanner was placed too close to the machine to be effective in an emergency.

We are working closedly with our customer to assist them with this application and help them achieve a safe and effective solution to this.

If you need any support with safety applications or other upgrades, please get in touch.. 

Parker SSD Microtach Replacements

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Microtach encoders, manufactured by SSD Drives for many years offered reliable transmission of sensitive high-frequency information in an electrically noisy environment.

The technology used a combination of an incremental encoder disk combined with micro-electronics to facilitate the use of single fibre optic transmission of the encoder pulses.

This gave a huge advantage of being able to transmit a noise-free signal over considerable distances.

However, time moves on and the Microtach is no longer available. The fibre optic cable, sending and receiving optics also degrade over time, affecting system integrity and reliability.

 

Link Rack

Fortunately, Optima can upgrade your ageing Microtach units with a modern equivalent that has exactly the same mounting arrangement. We also supply a new coupling with every encoder.

We use our own proven high-quality multi-sheathed cable to give the same reliable signal quality for the wired encoder equivalent. Distances up to 100 metres have been achieved with no signal degradation.

For this, or any other LINK hardware or software support, just get in touch. With over 100 years of combined experience engineering (and for some, designing!) the Link hardware, we have a solution for your obsolete hardware.

Parker SSD Link Upgrades
Link Programming Services

Cloud-based data dashboards

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If you want to see how your machine or process is operating day in day out from anywhere in the world, where do you start? 

An increasing number of companies are turning to remote cloud-based solutions for machine monitoring. Optima are pleased to offer our Cloud-based solution which keeps your automation hardware safely behind a secure firewall.

The video below shows a basic demonstration dashboard. If you would like to know more then please get in touch – we like to talk!

This video gives a very brief demonstration on how our Remote Access and Cloud Logging System can help you keep track of how your machine is performing. See when the machine is started, stopped, realise production metric data straight to your mobile, desktop or tablet.

We have been trialling our remote machine data dashboards #iot #industry4. These allow real-time data to be visualised from any PLC anywhere in the world to a PC, tablet or mobile ‘phone anywhere in the world! The system can communicate over 4G, Wi-Fi, or a direct Ethernet connection. From Kazakhstan (yes, we do have two units out there!) to Kendal (we haven’t got one there yet…), we have you covered for a very low monthly cost.
Our remote reporting dashboards which can send #production #reports by #email will shortly be ready for release.

With the increased risk of hacking of industrial devices becoming ever more prevalent Security Week – New Vulnerabilities Can Allow Hackers to Remotely Crash Siemens PLCs it’s not as simple as just hooking your PLC onto your local network.

Most of our clients prefer a SIM-card based system. The benefits of this system are that the equipment is always live whenever there is cellular reception available. Our range of antenna options mean that reception is possible even in the most remote locations.

For more information, please contact info@optimacs.com

Mark Lane.

Siemens Transform Event

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Join Optima at the Siemens #Transform2022 Conference being held at the Manchester Central Convention Complex on 12th and 13th of July to explore how digitalisation of industry is being accelerated. For more information and to register for a complimentary space, see #Transform2022. Some of the key areas are:

  • Edge and Cloud Data computing for machine diagnostics
  • Improving plant operational efficiency and reducing energy consumption
  • Use of resilient forms of energyJoin Optima, your trusted Siemens Automation and Drives partner at this event. It is the largest event that Siemens have ever organised in the UK so it set to be an event that shouldn’t be missed!

Rockwell Extended Warranties

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If you have recently upgraded your machine or purchased Rockwell Automation hardware from Optima, a simple registration process can protect your investment.

The benefits for your business include:

Registration is easy. Simply scan the QR Code on your product packaging to get started or use our registration portal to add your products manually. Once your registration is processed, you may enjoy an extended warranty, easy access to your products’ documentation and updates on the product lifecycle status.

Successfully registering your product can result in a warranty extension on top of our standard manufacturer warranty. 

Just one way that Optima can help you get the most from your upgrade.