Cost savings, easier control system design and smaller control panels are just some of the important benefits that have been enjoyed by Sovereign Labelling Systems.
Sovereign Labelling Systems manufactures an exceptionally wide range of machines that includes high-speed labelling systems for the dairy industry, linerless label applicators and cross-web labellers, as well as stretch and heatshrink sleeving machines. While much of the company’s output is destined for use in the food and pharmaceutical sectors, it also supplies equipment to many other industries.
A little over a year ago, the company was building automation systems for its machines using equipment from several suppliers. One supplier was used for programmable controllers, while another supplied inverter drives and yet another the sensors. It was suggested that Sovereign would gain significant benefits by changing to a single source supplier for all of its automation needs. Market research showed, however, that very few suppliers were in a position to meet Sovereign’s diverse requirements.
Sovereign had previous experience of working with Omron and had found both its products and the support to be excellent. It was no simple decision to make the change however, as many technical issues were involved, not least the need to convert the programs used in the existing PLCs so that they were compatible with the new equipment.
The benefits on offer were persuasive. In particular, Omron could supply motion control functionality (up to four axes) within its compact CP1H PLC controller. Not only would this reduce the amount of panel wiring needed, it would save space, allowing a smaller and less costly control panel to be used. It would also simplify the control programs, since the motion controllers would have direct access to PLC data and vice versa.
In addition, Omron could offer a compact electronic graphical HMI unit that would integrate easily with the PLC. Previously, Sovereign had been using text-based HMI units on its smaller machines with graphical units fitted to its high-end products. The low cost of the new graphical HMI panels meant that it would be possible to use them across the whole range of Sovereign equipment. In addition, dealing with a single supplier simplified the placing and management of orders allowing even further cost saving.
In the light of these benefits, Sovereign made the decision to move to Omron as its sole supplier of major automation products. The scope of supply includes compact and versatile CP1H programmable controllers, Smartstep servo controllers that combine the economy of a stepper drive with the performance of a servo, J7 compact inverter drives, NS HMI panels with colour touch-screen displays, photosensors and proximity switches. The machines in which these products are used are typically designed for standalone operation with the excellent networking capability of the products used to create links between the inverter drives and the PLCs.
“The level of support we received was truly exceptional. For example, Omron even put some of their own application engineers into our offices to help with the work of converting the PLC programs and to guide us through the other design modifications made necessary by the changeover,” said Keefe McCarthy, managing director of Sovereign Labelling Systems. “Whenever we have subsequently needed support, it has always been available. Also, the Omron engineers clearly have a good understanding of the type of equipment we manufacture, which enables them to provide accurate and helpful advice.”
The adoption of Omron equipment has also led to additional benefits. Sovereign has found that the integration of the motion controllers with the PLCs has improved overall responsiveness, as communication delays are virtually eliminated. This translates into better label placement accuracy. Also, the fitting of graphical HMI terminals has enabled diagnostic facilities as an aid for the engineers commissioning and maintaining the machines.
For more information contact Terry McIntosh, Omron Electronics, 086 066 7661, [email protected], www.industrial.omron.co.za
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