Saving valuable space on packaging machine plant

November 2000 System Integration & Control Systems Design

An OEM of food packaging machines produces a variety of packaging machines. Each machine has a small operator interface and a PLC with 24 to 80 digital and analog I/O.

On every machine, the electrical panel is limited by the size of the machine. The footprint dictates how much available space is available for control. The limiting space greatly reduces flexibility and the ability to expand packaging options.

This is where the OCS (operator control station), from GE Fanuc, was a good choice, as it combines the OI and PLC functions into one small package that can be mounted in the operator's console. "We can use our limited panel space for other devices," said the design engineer. "We immediately recognised the advantages of the OCS when it was presented to us. Being able to do everything within one programming package will save us days of engineering design and checkout time. Not to mention the time saved by eliminating the integration task of the OI, PLC, and network."

The OCS controllers are powered by an Intel 296 microprocessor that has similar processing power capability to that of the Intel 486 mP. Each controller contains the hardware for a Control Area Network (CAN) interface that can be configured for CsCAN, or DeviceNet, Slave. The OCS comes in either a 2 or 4 line LCD display.

The optional SmartStack I/O modules are available in various DC and AC discrete voltages, as well as Analog, Thermocouple, and RTD versions. Each Smart Stack module is equipped with a removable I/O connector. Additional modules available include a high-speed counter, stepper motor controller, multi port ASCII/BASIC, and strain gauge.

The advantage of the OCS is the fully integrated controller, I/O, operator interface and networking in one package. The Cscape software combines the graphical ladder programming with the operator interface and networking to decrease the development time required. By combining the controller and operator interface, panel space is greatly reduced.

The speciality modules enable the OEM to expand into motion applications that were not available with their current controller. By using the Stepper Module and GE Fanuc SL Servo system, the packaging machines were more efficient and increased production capacity. Another advantage of the OCS is the standard CAN network. OEMs can now provide a high-speed network for their end customers at no extra charge.

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