Steel Tube Manufacturing Control System Integration
Steel ManufacturingLeading steel tube manufacturer specializing in painted pipe production
Challenge
- Quick turnaround requirement for control system integration
- Multiple equipment pieces with diverse control systems
- Various generations of Rockwell processors (PLC-5 to ControlLogix L63)
- Different communication protocols requiring harmonization
- Equipment from multiple sources needing unified control:
- Existing conveying units
- In-house designed elevator/lift-station
- Used pipe swager from sister facility
- Upstream paint line requiring permissive controls
Solution Delivered
Programming Services
- ControlLogix L63 program modification and consolidation
- Removed non-essential logic for streamlined operation
- Adapted systems for equipment transfer from sister facility
- Configured for new location installation
Equipment Integration
- Mair Bundler control integration
- Elevator control logic development:
- Implemented sequence of operation from client specifications
- Configured repurposed PowerFlex 70 VFDs
- Exit Conveyor system integration
- Bundle Accumulation Table with permissive and pause logic
System Upgrades
- Migration from ControlLogix L63 to GuardLogix L81ES processor
- PLC-5 program modification for GuardLogix communication
- Implementation of dual channel safety devices and safety relays
- VFD reconfiguration for swager head relocation
- Swager PanelView HMI graphics development
Results
Immediate Outcomes
- Successful integration of diverse equipment into unified system
- Implementation of best practice programming standards
- Functional central control system
- Seamless communication between different processor generations
Operational Benefits
- Automated paint, swage, and bundling capabilities
- Flexibility to handle various pipe diameters and lengths
- Enhanced safety through improved controls
- Efficient equipment repurposing
Business Impact
- Streamlined manufacturing process
- Increased operational efficiency
- Successful equipment redeployment from sister facility
- Modernized control infrastructure
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