Electrical System Upgrade of PVC Aperture Fabrication Machinery

Scope:
Retrofit existing machinery by replacing substantial part of the critical electrical components of the system.
Customer type of business:
PVC Apertures Fabrication
Service:
Retrofitting, Feasibility study, Design, Disassembly of old parts, Assembly of new parts, Programming, Documentation, Commissioning, CE, and ongoing support.
The challenge:
To install a new electrical system onto an existent mechanical system.
Additional info:
Read below for Overview and Process

Overview:

Our client is a leading fabricator of PVC apertures in Malta, utilizing specialized machinery to execute predefined cuts into PVC profiles based on software-generated models. This process helps increase efficiency, minimize material waste, and ensure consistent quality.

The client faced significant challenges due to the aging electrical components, which led to frequent unplanned downtimes and reduced productivity. Additionally, the lack of adequate support from the original equipment manufacturer (OEM) made troubleshooting and maintenance increasingly difficult.

Project Objective

The main objective was to upgrade a substantial part of the electrical system while preserving the existing mechanical infrastructure. This upgrade aimed to eliminate reliability issues, enable seamless integration with the current digital workflow, minimize downtime during implementation, and provide local, highly specialized support for the upgraded system.

 

Machinery Upgrade Process

  1. Original Machinery Assessment and Feasibility Study
    The upgrade began with an in-depth assessment of the existing system, evaluating mechanical, electrical, and software components. Eventually, outdated electrical components such as servo drives, motors, and control panels were identified. Moreover, the existing software was studied to determine how it interfaced with the control system, ensuring compatibility with the new hardware.
  2. Component Selection and System Design
    After the assessment, Beckhoff components were selected for the upgrade. As proud partners of Beckhoff for its superior quality, the following key components, such as the generation of AM8000 servo drives, One Cable Technology(OCT) Cables, I/O modules, and industrial PCs, were chosen to match the specifications of the legacy system.
  3. Off-Site Engineering and Testing
    To minimize disruption to the client’s operations, the new electrical and control system was developed off-site. The PLC and motion control programming were completed in advance using TwinCAT, Beckhoff’s software development environment, along with customized software designed to interface with the existing system. In addition, functional testing was conducted to ensure the new system would integrate seamlessly with the mechanical layout and existing software workflows.
  4. On-Site Transition and Commissioning
    To proceed with the on-site transition, the old electrical cabinet and components were dismantled, and the new Beckhoff-based control panels, drives, and servo motors were installed. The electrical upgrades were retrofitted into the existing mechanical framework, eliminating the need for major physical modifications. Comprehensive on-site testing and fine-tuning were conducted before the final commissioning.

 

Results and Benefits

The upgrade resulted in a highly reliable system, significantly reducing the risk of downtime that could previously halt the entire production line. The client now benefits from rapid, high-quality local support, thanks to the expertise of a dedicated team of engineers familiar with the new system. Moreover, the open architecture of the Beckhoff system allows for future scalability and the potential for further integration of automation modules, ensuring the system remains future-proof.

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