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Completing a controls upgrade

Shrink wrap machine manufacturer maximizes machine design flexibility with centralized PC-based controls and industrial Ethernet.

Pw 8399 Conflex 02

Conflex (www.conflex.com) wrapping machines are used primarily in the food, consumer goods, electronic media, and printing industries. Customers in these sectors demand user-friendly machines with intuitive interfaces. So it’s hardly any wonder that Conflex was an early adopter when servo technology started kicking in a few years back.

The firm has continued to evolve, too. In particular, the ServoFlex film seal wrapper has seen dramatic changes from its previous incarnation. The old ServoFlex design utilized numerous intelligent drives that handled the automation and motion control aspects of the machine. The required programming time for numerous drive controllers was cumbersome. “It was a three-servo system—each axis had its own controller that had to be individually programmed,” says Mark Lorenz, electrical applications engineer at Conflex. The drives weren’t equipped for Ethernet connectivity either, which hampered Conflex’s networking efforts.

Adding or removing I/O from the system further complicated the problem. “If even a single I/O point failed in the intelligent drive system, we’d have to replace entire boards,” explains Lorenz. “It was also very expensive to replace the drives themselves whenever we had a failure. It became apparent that in order to be flexible and better manage our controls, we needed a new solution.”

In late 2005, Larry Koenigs, electrical engineer at Conflex, encountered the Wisconsin region sales manager for Beckhoff Automation (www.beckhoff.com). “At the time, we had made what we thought was our final decision on a new platform from a major automation and controls vendor,” Koenigs said. “It was an acceptable motion controller with PLC functionality, but it didn’t have all the programming and design flexibility that we hoped for. We just accepted that we were going to have to put more time and effort into the controls design than what was ideal. The call from Don just happened to arrive at the last possible moment. He called on a Friday when we planned to order our controllers that following Monday.”

Conflex then learned about the DIN rail-mounted Beckhoff CX1020 embedded PC and TwinCAT automation and motion control software. “The solution put forward by Beckhoff turned out to be exactly what we were looking for and allowed us to create the electrical controls system we wanted,” Koenigs said. “We were impressed enough with Beckhoff PC-based controls that we decided to make a major change of course at the last possible minute.”

In addition to being a good technological match in terms of openness and flexibility, the Beckhoff system was attractive from a cost perspective, too, adds Koenigs. Also appealing is that the TwinCat software complies with IEC 61131-3, a programming standard that is gaining increasingly wider acceptance on a global basis.

The revamp begins

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