Cheswick, Pennsylvania-based Miller Process Coating is an OEM that
specializes in turnkey solutions for cylindrical silkscreen printing
applications. “The major technical challenge that Miller's customers
face is printing on a tapering round surface,” says Tim Bradac, key
account manager for Omron Industrial Automation. “Most of the machines
they build are used by companies that print bar glasses—pint glasses for
draft beer. Print consistency was the number one problem they were
trying to address when we started working with them.”
Part of the
challenge for Miller was engineering support. While they had internal
resources for mechanical engineering, they contracted out electrical
engineering to a competitive vendor for controls. Unfortunately, the
support they received from that vendor was sporadic.
“We offered a
total solution,” says Bradac. “As a solutions provider, we were there
from start to finish, helping with everything from machine
specifications to machine fabrication, including training on how to
program the machine and providing post-production support. Once a
machine is delivered to one of Miller’s customers, Omron Industrial
Automation, as a global company, is there to support those customers,
wherever they are.”
Printing the Perfect Pint Glass
The specific package Omron Industrial Automation provided to Miller
consisted of a Trajexia stand-alone advanced motion controller and four
touchscreen Human Machine Interfaces (HMI). The 64-bit stand-alone
Trajexia controller, with built-in EtherCAT master, provides a
significant improvement in machine performance and accuracy, allowing
them to run their machines faster for higher productivity during the
same working hours. The Trajexia TJ2 ensures the fastest operation at
the highest accuracy by providing a short minimum system cycle time for
up to 64 axes and using native 64-bit integers to minimize data
conversion and accelerate processing. The Miller application uses nine
of the possible 64 axes available.
"This Omron solution does a fantastic job in meeting our current
requirements, but it’s also reassuring to know that the controller can
coordinate 16 axes in 1ms for our future machine platforms as they
expand into higher ranges," says Pat Quattrocci, president, Miller
Process Coating.
One of the HMIs acts as a master that stores all the recipe
data for the various print models Miller has, and the other three are
slaves for set up and starting or stopping operation/production. As a
four-sided machine, there are four operators working on it at any given
time. The machine provides each operator with the ability to do his or
her own prints.
“The use of EtherCAT was very important because it allowed us to
communicate easily through a slip ring,” says Bradac. This is a rotary
machine with a set of slip-rings that run up through its center. The
EtherCAT network is ideally suited for such an application because you
can disconnect the wiring, put it through a slip-ring and reattach it
easily.
That was just one benefit of the EtherCAT; others include its
simplicity, connectivity, and that data could be pushed through at
unmatched speed. EtherCAT was used in this instance for both I/O and
motion control.
“The biggest benefit of using EtherCAT in this application was
that it allowed us to store the profile of every drive inside of the
Trajexia,” says Bradac. “By storing these profiles, should a drive go
out via an electrical spike or some unforeseen problem, the customer
will be able to replace the drive with a new one and all the
configuration information transmits over EtherCAT directly into the
drive automatically. The setup is immediate.”
Major Benefits
Another important benefit to Miller is the ability to write and store
recipes on the Omron NS-Series operator interfaces and transmit them
directly to the Trajexia Motion Controller. Storing recipes on the HMI
gives Miller’s customers the ability to write custom applications
without having the operators touch the program. “Miller can create a
simple spreadsheet in Excel and use that to enter the parameters they
need,” says Bradac. “This is all set up just prior to machine shipping,
at which point the customer will have the ability to input data with a
spreadsheet into the HMI. That data will be stored in the HMI, and from
there it can be transmitted to the motion controller.”
Walking the Walk
Omron Industrial Automation quickly proved to Miller that it truly
stands by its promise of total customer service—it was demonstrated
throughout the entire process right into Miller’s order book. Miller had
a customer that was still deciding on which machine manufacturer to
choose, and Omron Industrial Automation invited that customer to come to
the Omron headquarters to examine its laboratory facility and see what
Omron Industrial Automation was all about as Miller’s partner. “We were
able to show them what the motion controller solution would look like,
how it would act, and all the engineering capabilities resident in our
lab,” says Bradac. “After the meeting, the customer felt confident that
going with Miller would be the right choice, and that they would be
getting a machine of the highest quality that would be supported at the
highest level.”
Right from the get-go, Miller saw the difference in working with
Omron Industrial Automation. “For the first machine they built, when
using a competitor’s product, Miller had to make numerous trips to
Canada to fix unforeseen problems because there was no one else to help
the customer,” says Bradac. “Because they didn’t have deep internal
electrical engineering resources, it was an especially difficult
situation to address. With Omron Industrial Automation, and with the
global support we provide, they’ll never have to face that situation
again,” concludes Bradac.
Something everyone can raise a glass to.
