Controls and Automation System (project Bolt)

Satellite control panel

• Location – in the central operator island created by the north and south labelling systems adjacent to conveyor BLT-1-P2 on the drawing east side of this conveyor
• Facilitates operation of conveyor system at a time when an operator is in position attending to the operation of one or both of the labellers
• Enclosure will be mounted on a swivelling stand to rotate 180 degrees allowing equal accessibility
• Allen Bradley PanelView Plus 7 HMI interface p/n 2711P-T9W21D8S for operator control with controls interface – mirror of unit in main control panel
• Hoffman NEMA 4X 304 stainless steel junction box enclosure measuring 20″ wide x 24″ high x 6″ deep – p/n CDS20246EMCSS (or equivalent) to house the HMI and door switchgear
• Includes switchgear for three conveyor zones: 800T-FXTQ24RA5 illuminated ESTOP, RESET and START
• We have not provided any external temperature regulation devices for this enclosure because the HMI itself does not generate much heat.
•  Includes electrical schematics, PLC programming, servo configuration and programming and HMI programmin

Controls – field electrical

• Items to include but not limited to the parameters below as long as the overall extent of the scope of supply is equivalent (field work is estimated and shown with the scope of installation.
• Sent – the following:
• Heartbeat signal (BOOL)
• Carton Count (DINT)
• Box Count (DINT)
• Actual Speed (cartons over 15sec window) (REAL)
• MMI Alarm message number (DINT and provided a list of faults)
• Line faulted (BOOL)
• Vertical control enabled (BOOL)
• Change over complete (BOOL)
• Received – the following:
• Request change over (BOOL)
• Production code (DINT)
• Production name (STRING)
• Recipe number (DINT)

General description:

• Two end driven belt assemblies – for initial metering – left and right side belts
• The brake only allows a carton to proceed forward when the leading edge will touch the infeed contact point (quadrant) of merging belt with a suitable gap present between the leading edge of the carton entering and the trailing edge of the carton leaving the merging conveyor
• Low-inertia brushless servo motors (2) Allen Bradley VPL series, 480 V – p/n VPL-B0631T-PJ12AA
• Alpha (Wittenstein) LP series in-line planetary gearboxes (2) – p/n NP005-MF1-10-1A1
• Flanged anodized aluminum timing pulleys are used for drive and tail. They are grooved to accept K6 profile guiding on the timing belt.
• Individual 3/4″ thick anodized aluminum plates will each house the AC servo motor and gearbox.
• Individual, to each belt assembly, a  ½” thick lower plate will be above the timing belt which is bottom most. The plate is separated from the upper motor mounting plates with bolted stainless steel spacers and serve to provide bearing separation on shafts to accommodate the side loading onto the pulleys. All drive and tail shafts will be vertically fixed with aluminum guide blocks, with bushings,  located between the upper and lower plates. This permits easy and repeatable belt tensioning.
• The side belt assembly located on the operator side (L2-P3B-1) will provide adjustability to carton widths ranging from 5-1/2″ to 12-1/2″ with Igus SLW-2080 series guided, handwheel actuated, module with numerical readout.
• The Igus SLW-2080 adjustment module will be supported by an anodized aluminum plate base with gusseted 40 mm x 40 mm aluminum extrusion that permits precise initial machine set-up adjustability
• The side belt (L2-P3A-1) on the non-operator side are supported by an anodized aluminum plate base with gusseted 40 mm x 40 mm aluminum extrusion that permits precise initial machine set-up adjustability
• This assembly will be adjustable for width position and parallelism for the purpose of initial set up, but afterwards will be fixed in position
• Infeed guides are bolted to the bottom plates that consist of 11 gauge stainless steel polished flat bar with suitable lead in angles
• These side belts will be housed within a machine base / safety enclosure which will be constructed from a welded 1-1/2″ x 1-1/2″ x .120″ wall tubular stainless steel with slotted, welded tabs that provide initial machine set-up adjustability and provided with fixed, 1/4″ thick polycarbonate panels. From a safety perspective, the enclosure is mandated as a result of cleat / side  belt mechanical interface and the crush points present with cleat to adjacent fixed assembly interface. Enclosure consists of  five swing doors (5)  with a 30 mm x 30 mm aluminum extrusion frame, polycarbonate panel and Schmersal BNS-33 magnetic door switch will provide operator access.
• Stainless steel pinch guards are bolted to the infeed of the side belt assemblies at the aluminum top plates

Structural features:

Belt:

• Blue Silam EM 6/2 00+02 high coefficient of friction polyurethane with Unibar UCM36LXSP recessed lacing.
• Supplied with underside bonded, K10 10 mm wide PVC , notched “O” section”V’ guide.
• Brecoflex BB61XC010660001 timing belt with cover.
• with a solid K6 self tracking guide with a 4.7625 mm thick [3/16″] red Linatex back cover ground for consistency.
• 35 Shore C durometer for high grip.
• Truly endless provides long life.

Electrical:

• Controlled from centrally located panel with Allen Bradley Kinetix 5500 servo drives (2) p/n 2198
• Seven Hubbell HBL-DS3-AC motor disconnects with monitoring for all conveyors that are supplied above.
• Frequency drive rated cabling will be used from the motor terminal box to disconnect.
• A distributed I/O on ethernet network is provided via TWO 16 point Allen Bradley Armor Block p/n 1732E-IB16M12DR remote I/O  modules
• All door switches (7) are monitored and recorded on the HMI.
• Two Allen Bradley pendant style control modules at extreme ends of the L2-P4 packing face. One pendant includes a 22 mm E-stop. The other pendant includes: 22 mm E-stop, reset, cycle stop and start.
• One ethernet/IP shaft encoder Turck p/n T8.5020.3882.1024 mounted to conveyor L2-P4 tail shaft
• One ethernet/IP shaft encoder Turck p/n T8.5020.3882.1024 mounted to conveyor L2-P7 drive shaft as specified by Delkor
• Inductive proximity sensor Sick IMB12-08NPSVC0S p/n to detect cleat position and clear encoder count
• Jam detect sensor consisting of a Sick p/n WTB2S-2P3130 located at start of L2-P4 used to confirm space between cartons
• Two clear sensing retro-reflective photo-eyes Sick p/n  GRL18SG-F2332 that are mounted between L2-P3A1 and  L2-P3A2 to control the indexing of cartons
• Initial power up and testing at our facility and breakdown for transport .
• Electrical field inspection of all high tension field wiring by QPS on site
• All communication with adjacent control systems, more specifically Delkor Systems, will be via RJ45 ethernet
• Wiring is pre-routed through under conveyor mounted stainless steel wire tray – Thomas & Betts ETQ2004SS10 2″ x 4″ Quik-Lok stainless steel wire tray with galvanized cover
• System will be mostly pre-assembled in our facility, tested and partially dismantled again for shipping
• The exception to the pre-testing statement above is that conveyor L2-P4 will be assembled as tail, drive and two intermediate bed sections only due to space constraints
• Four Allen Bradley Kinetix 5500 series servo amplifiers with line filters
• Five Allen Bradley PowerFlex 525 AC frequency drives, each with an infeed line reactor
• Allen Bradley Compactlogix p/n 1769-L27ERM programmable controller with input and output modules and capacity for up to four servo axes
• Allen Bradley PanelView Plus 7 HMI interface p/n 2711P-T9W21D8S for operator control and set-up for SCADA
• Hoffman NEMA 12 epoxy power coated carbon steel enclosure measuring 36″ wide x 60″ high x 12″ deep – p/n A60H3612DLP3PT
• Two Allen Bradley 1783-US8T Stratix unmanaged switches
• One Allen Bradley 1783-NATR IP configurable switch
• Two Schmersal p/n SRB301MC safety monitoring relays
• 480 VAC / 3 phase / 60 Hz – 45 Amp supply
• One Allen Bradley 24 VDC power supply 1606-XLE120E 120 watt
• Allen Bradley 22mm switch gear mounted to enclosure door – 800F series
• Enclosure air conditioning – Rittal TopTherm Blue p/n 3304.504 – 3,750 BTU capacity – door mounted
• Includes electrical schematics, PLC and HMI programming and servo configuration
• Electrical inspection and certification of the panel only prior to shipping by QPS

Twin roller guide mount at infeed of Delkor rejection

• Flexible roller guide 580-603302 mounted on metal profile
• Frame in acetal POM
• Roller in Polyamide PA white
• 26″ wide guide face

Gravity roller

• 24″ between frame
• 1-3/8″ outside diameter x 18 gauge galvanized tube
• 102228-O unground, crimped, oiled bearings
• 5/16″ hex mild steel axle, 25″ long
• Spring retained on one end

Tapered gravity roller #40343

• 16″ between frame
• 1-1/2″ outside diameter to 1″ outside diameter x 18 gauge zinc plated tube
• 102175-O unground, crimped, sealed, oiled bearing
• 5/16″ hex mild steel axle, 17″ long Spring retained on one end
• North American or Japanese roller or ball bearings – NTN, NSK, FAG or equivalent
• Martin sprockets, timing pulley and gears
• Habasit series 82025″ and 4.00″ acetal tab chain conveyor
• Pacific Bearing linear ball bushings and ground shafting
• Igus SLW series integrated linear axes for sub-assembly adjustable positioning
• Festo EGC series toothed belt or ball screw actuated servo axes.