Various Press Automation & Controls

Various Press Automation & Controls

Uncoiler Automation & Controls

As an integrator, we see the need to have knowledge not only of the press controls, but of the entire press line. That's why we've engineered and commissioned projects which included uncoilers, straighteners, feeders, transfer systems and stacking/destacking units.

Having an integrator who knows more than simply the press controls will not only save you time and money, but will help speed up your production by syncing your entire press line to work together.

If you have any questions about your press line with regards to functionality or any other problems, contact us using the form below or at 1-800-TTOLEDO.

We've interfaced with or designed the following:

  • Uncoilers
  • Straighteners
  • Feeders
  • Transfer Systems
  • Stacking/Destacking Units

Click Here To Download Press Control RFQ

Case Study #1

Case Study #1

Control retrofit on a Komatsu blanking line:
The original blank line was installed in the 1980's. Not only did the controls not meet current OSHA and ANSI specifications, but over time the electrical controls started causing excessive downtime. Part of the downtime was attributed to the controls being difficult to troubleshoot. Another problem was that many of the existing components were obsolete. They were not only very expensive to replace, but very difficult to get. This is the only blanking line our client has and it is the sole blank supplier to four large mechanical stamping presses at their facility. Our client was looking for a complete solution provider, including a turn-key installation. They turned to Toledo Integrated Systems for help. With our past experience on other projects, we had proven ourselves to be competitive, reliable, and on-time.

Blank Line Equipment Break Down: There are several pieces of equipment that make up the blank line. The controls on all of these pieces needed to be replaced. Our design allowed for communication between each of them so that the line could run at maximum efficiently. Starting where the steel coil is loaded, the equipment consisted of:

  • Dual coil cars
  • Uncoiler (split style)
  • Material washer
  • Power straightener
  • Material loop control
  • Adjustable side guides
  • Komatsu feeder
  • Komatsu 400-Ton straight side mechanical press
  • Unloading conveyor
  • Side piler / part stacker
  • Main piler / part stacker (dual output)
  • Two automatic pin pallet carts
Coil view from blank line

The Solution: In looking at the size of the project, it was determined that we needed to break it down into three manageable sections. By supplying new controls for the entire blank line, we would be able to integrate all three sections seamlessly. The decision was made to use Allen Bradley ControlLogix PLC's that incorporated DeviceNet and Ethernet to communicate to the distributed I/O, PowerFlex 700s drives (w/ DriveLogix) and the operator HMI's. Toledo Integrated Systems provided the engineered solution, hardware, programming and the complete installation.

Press view from blank line

It boils down to: Controlling 33 electric motors + 5 AC frequency drives + monitoring 23 resolvers + 3 safety zones + programming 2 Allen Bradley ControlLogix PLC's with over 900 I/O points + 3 operator HMI's + writing over 2,700 lines of PLC code + drawing 215 electrical schematics.

Results: Prior to the Toledo Integrated Systems' retrofit, the blanking press controls were obsolete and did not meet current OSHA and ANSI specifications. The blank line was only able to run at 60% of its maximum speed and the downtime was becoming an issue. After the retrofit, the blank line is up to date and is now able to run at top speed, while keeping required quality specifications. The die change-over time has also decreased due to an ADC (auto die change) program that was added to the line. The ADC automatically guides the set up person through the change over, step by step. This ensures that each step is done in sequence and the process will not continue until each step is completed. Overall production has increased due to the new controls and new improvements that were made to the blank line.

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