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Case Studies

Systems Integrator Relies on Advanced Control to Help

Reduce Costs, Improve Machine Safety and Optimize Output

Allen-Bradley GuardLogix safety control and Kinetix Integrated

Motion help turn safety into a competitive advantage

The Quigg Team leveraged the benefits of Rockwell Automation Integrated Architecture™ on a press application, similar to the one shown in this photo, for a Tier 1 supplier. The Integrated Architecture allows safety, automation and motion applications to be done on one control platform, using one set of common components and one program. Thanks to this solution, the Tier 1 customer met safety requirements and exceeded production goals.

Results
 

Background

When automotive or aerospace companies come to Quigg International for an automated metal-stamping system, vice president Joe Quigg is eager to show them how an innovative design and advanced technology can deliver a return on investment that will pay for their upfront costs.

The systems integrator, located in Tecumseh, Ontario, specializes in implementing industrial automation solutions – ranging from motion control to safety systems – for metal stamping. Quigg and his team understand that customers come to them with the need to help improve machine performance and reduce costs.

The team did just that when a major automotive client came knocking, looking to upgrade the automation on its existing stamping press, improve its employee safety, and meet compliance demands. The machine upgrade also went one step further, by helping the customer increase overall productivity to the tune of about $2 million in one year.

Challenge

On the original system, a forklift operator loaded sheets of steel next to an operator load station. The operator manually loaded the steel onto the stamping press one piece at a time. While this might have been acceptable in the past, it put the operator close to the most dangerous part of the machine. So, the Quigg team determined to add a robot on the front end to do the high-speed, heavy lifting of steel onto the stamping press, and, in so doing, move the human operator out of the hazardous area. This allows operators to supervise the robot from a safer distance and help make sure the line operates smoothly.

Quigg and his team set out to find a control system solution that would integrate these three disparate control disciplines into a single integrated system. After looking at several options, they selected Rockwell Automation based on the integrated control system it could offer.

Solution

Traditionally, this type of system would use three different control mechanisms – one each for safety, motion and automation, each requiring its own hardware, training and software. Using disparate systems requires more training, more equipment and more maintenance, all of which increase operating costs for a company.

The Quigg team worked with Rockwell Automation to leverage their Integrated Architecture, which integrates safety and motion into one control platform and uses one software program and one set of spare parts, while helping to meet the required safety criteria. The advanced control technology allowed Quigg's team to build a machine with safety interlocking devices, including Allen-Bradley Guardmaster gate switches, designed to keep personnel away from the stamping press, while providing a more flexible, standardized platform.

The upgrade included an Allen-Bradley GuardLogix controller with Allen-Bradley Kinetix Integrated Motion, EtherNet/IP communications, PanelView + Operator Interface and system programming using Allen-Bradley RSLogix 5000 software to program the automation, motion control and safety functionality in one environment. GuardLogix controllers and Kinetix Integrated Motion are part of the Logix control platform.

The platform provides engineers with multidisciplined control from a common programming environment, common networks, and common control engine, along with integrated Safety Integrity Level (SIL) 3 control in a single environment. Using the GuardLogix controller and implementing Category 4 safety circuitry allowed Quigg’s team to build a machine with Allen-Bradley Guardmaster interlocking devices to help prevent personnel from entering hazardous areas of the machine. This allows the robot and press automation to run production without the typical slowdowns caused when operators need to enter potentially dangerous areas.

“If metal scrap needs to be removed or the press needs maintenance, the system still has the safety gate interlock switches and light curtains, and all the things that protect people who have to access the cell for maintenance and repairs,” Quigg explains. “The GuardLogix controller monitors the light curtains and gate interlock switches, and controls the machine cycle, helping to make sure the press operates safely.”

One of the most unique challenges of this project was the need to integrate press, motion and safety controls into one system,” Quigg says. “GuardLogix solves this problem by being part of an integrated control architecture that simplifies programming and configuration, and improves system reliability.” The Allen-Bradley Kinetix 6000 and Kinetix 7000 servo drives feature a safe-off function designed to help improve safety while maximizing machine availability. With the safe-off feature, the drive output is disabled (with SIL 3 integrity) to help eliminate motor torque without the need to remove power to the drive. Tasks such as machine setup, cleaning, removal of jams and other maintenance work can be accomplished without removing power to the entire machine. As a result, machine restarts are faster, which helps reduce downtime. Additionally, extraneous components such as output contactors can be eliminated, simplifying machine design, minimizing panel space requirements and reducing overall system cost.

Results

The machine upgrade met all of the customer’s safety and automation criteria – plus, proved its value in reduced downtime, increased productivity, and improved bottom lines for the system integrator and the end user. “The customer was delighted with the multiple benefits provided by the integrated platform,” Quigg said. “These benefits included a more compact, space-saving design, fewer parts, less training, and less software, all of which helped reduce maintenance and ownership costs.”

By using the Integrated Architecture from Rockwell Automation, it helped Quigg save more than $50,000 on costs for hardware, design, tests, installation and start up, compared to conventional costs of nearly $90,000. As an additional benefit, employees are working in a much safer environment. Furthermore, providing the safer environment helped with productivity – and also helped production capacity increase.

The new robot moves 500 pieces of steel per hour, compared to a previous peak of 120 parts per hour. All told, the automotive manufacturer realized savings of approximately $2 million in extra production capacity during the first year, thanks to faster start up and a higher production rating.

“Safety and production can go hand in hand,” Quigg says. “We’re proving it here. I’m proud of our ability to engineer a solution that helps meet and exceed our customers’ expectations. With the help of Rockwell Automation, we were able to provide our customers with a safer place to work, increased production and reduced equipment costs.”

The results mentioned above are specific to Quigg International’s use of Rockwell Automation products and services in conjunction with other products. Specific results may vary for other customers.