SINAMICS G Smart Access Module

Posted on February 14, 2025

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

Scalable motion control systems from Siemens and Optima

Posted on February 12, 2025

Optima are pleased to present our holistic system approach for motion control applications in the field of basic automation

Using the single-axis servo drive systems, SINAMICS S200, S210, and the new controller SIMATIC S7-1200 G2 we are able to offer a competitive solution for Kinematics, Positioning Cams, Speed axis and a host of other functions.

Performance and Scalability

• Enhanced processing power with dedicated communication performance and extended memory
• Supports up to 31 PROFINET devices and synchronized
program execution with PROFINET IRT
• High drive performance due to a fast current controller

Flexible machine safety

• A cost-optimized fail-safe safety hardware portfolio
• PROFIsafe communication for safe data exchange
between the controller and the drive system for safety
applications
• Drive-integrated basic and extended safety
functionality up to SIL3, PLe and Category 4

Efficient motion control

• Control of single axes, coordinated axes, and simple kinematics
• Integrated motion control technology objects simplifying
configuration
• Drive-integrated basic positioner function, SINAMICS EPOS

Increased data transparency

• Near Field Communication (NFC) for wireless access
to diagnostic and device data of the PLC
• SINAMICS Smart Adapter for wireless access between
the drive-integrated webserver and mobile devices or
to the SINAMICS Startdrive engineering software
• Drive-integrated webserver for easy commissioning

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

Posted on February 10, 2025

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

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.

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:

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.
Increased Production Speed: The upgraded machine operates at a higher production speed without compromising product quality, resulting in improved throughput.
Reduced Mainternance Requirements: The new configuration eliminated the need for regular recalibration, easing the workload on maintenance staff.
Improved Operator Satisfaction: Operators appreciated the simplified “one-touch” start functionality, which made operation straightforward and reduced the likelihood of errors.
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

Digital cloud-based asset monitoring is offered worldwide

Posted on October 8, 2024

Our new digital cloud-based services platform can be used worldwide. The software means Optima can monitor and track your assets in real time. You can view device history, schedule tasks and monitor the machine via the cloud. This keeps you informed of any issues as and when they occur. Escalation thresholds can be configured, so depending on the nature of the fault, the relevant people are emailed. The monitoring system can also give daily reports via email notifications with programmable triggers.

If the machine starts operting in an unexpected way, an email is tiggered, sending messages to your maintenance and response teams We can use the system
to diagnose the issues with your hardware and ship equipment to site to rectify the problem.

These online diagnostics can be viewed 24/7 and the software can bring to your attention any faulty systems, sometime even before a breakdown happens.

Please contact us for a no-obligation dashboard trial.

Full Project Turnkey Solutions

Posted on October 3, 2024

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

Posted on July 2, 2024

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

Posted on July 1, 2024

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.

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.

Accelerate your digital and sustainability transformation at Siemens Transform 2024

Posted on March 15, 2024

We are delighted to invite you to join us for
Transform 2024 – the technology showcase from Siemens.

Join thousands of participants and accelerate
your digital and sustainability transformation to transform the everyday, for
everyone, on 17-18 July at Manchester Central.

· Hear from, engage with, and collaborate with industry experts on key industry topics – from AI to the
industrial metaverse and decarbonisation.

· Experience where the real world meets the digital in an extensive technology marketplace and discover
Siemens Xcelerator – the open digital business platform.

· Work with an expert community to solve real-world challenges and co-create solutions to make your
organisation more competitive, resilient and sustainable.

As a proud partner of Siemens, we hope you will join us at Transform and become part of a community solving today’s most pressing challenges, together.

Click below to register your interest and to receive updates from Siemens on their unmissable schedule of talks and experiences.

https://www.siemens.com/uk/en/company/transform.html?stc=ukcg200474

Optima’s Siemens Solution Partner Accreditation for 2024

Posted on March 4, 2024

Optima are proud to maintain both our Siemens Drives and Motion and Factory Automation accreditations for 2024. Our Solution Partner status as Automation Drives verifies our status of application and system expertise, industry knowledge and project experience with Drives, IOT, Cloud and Edge Applications.

We implement tailor-made solutions with exceptional quality. Our partner accreditation forms part of Siemens’ commitment to their principle of “Ingenuity for life”. We use ingenuity and engineering skill to work on sustainable solutions for your automation tasks.

Siemens Solution Partners are the number one choice for the engineering, system integration and implementation of superior, tailored, future-oriented solutions. Under the Siemens Solution Partner Program, Optima join forces with Siemens by merging our application and industry knowledge with their product and systems expertise to deliver added value to our Customers.

This includes: Consistent, High Quality, State-of-the-Art solutions that increase plant productivity. Confidence that your current project will go well and will be easy to maintain because as a certified Solution Partner, we will use “Best Practices”. We have on-going training that demonstrates our expertise via a bi-annual certification exam which measures our engineers capabilities on both the theoretical and hands-on abilities with the system. Coordinated project planning, supplied with the software tools, training and premium hotline support for fast, smooth and highly efficient implementations of your projects.

S88 Solution Solves Obsolescence Issue

Posted on February 10, 2022

Addressing obsolescence is an issue facing many companies and failure to create a robust action plan can often lead to problems that not only affect the operation of a line or machine, but can also result in unfavourable issues that could have detrimental effects on quality levels and brands.

The dangers of obsolescence were identified early on at a leading British biscuit manufacturer in its mixing plant, where older hardware was not only showing its age in terms of performance and failures, but was also no longer part of a supported spares package. More information can be found here: Rockwell Automation Case Study