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Machine packaging, baling, shearing and process control

CLIENT: MACAULAY METALS - ROTORUA
PROJECT: 600 TON SHEAR/BALER

CLIENT: MACAULAY METALS - ROTORUA
PROJECT: 600 TON SHEAR/BALER

MACHINE AUTOMATION
PROJECT: 600 TON SHEAR/BALER
CLIENT: MACAULAY METALS  ROTORUA

Macaulay Metals

Taurus Baler/Shear

Macaulay HMI Machine Automation and Control  Panel

Custom programmed HMI Panel Master Control Panel Screen

CHALLENGE:

We were asked to electrically install, commission and test a 600 ton compression shear/baler that had been purchased as a refurbished machine from Austria, and shipped to New Zealand. Unfortunately, the supporting documentation was in German, and the machine coding and electrical drawings were in  Italian. In addition the wiring modifications made overseas were unfinished and incorrect, the schematic drawings supplied were for a different machine (similar but by no means identical) and the PLC programming contained multiple bugs. A major headache for the client and for us.

THE SOLUTION:

Always one for a challenge, side by side with our trusted mechanical contractors, we painfully worked through the schematic drawings, the field wiring and the plc logic. By a process of elimination, using a methodical and logical mindset, we forced or bypassed  plc inputs, limit switches,  sensors and push buttons, and then added additional cabling to work out exactly how the machine should operate. For cost and timeframe reasons, the client decided that  replacing the entire PLC out, was not a viable option short term (but likely a future option for upgrades) so we  opted instead to take the primary PLC outputs and feed them into our own  PLC with a simple custom program to make the necessary minor end changes required to give the desired control, monitoring and feedback via a custom programmed HMI screen.

The customer was extremally grateful for our willingness to assist, and our persistence and  prioritization of their project so that we  met the deadline and budget.

Schneider PLC control cabinet for baler process control and automation.

Existing Schneider Modicon M340 PLC control mounted in distribution panel with retrofitted  Schneider Zelio SR3 PLC automation upgrade.

HMISTU-655 Home Screen

Baler Machine HMI Control Panels

THE TECHNOLOGY:

We utilized Schneider Zelio SR3B261BD PLC modules with SR3MBU01BD RTU communication to provide the missing link automation of the machine field devices... and eliminate the archaic transistor board technology from early 1990's that was still in place despite a minor overhaul

We have the ability to easily implement  for  networking the custom built HMI program to provide the potential for remote monitoring and even remote operation if required using the Schneider  HMISTU-655 HMI screen.

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