Mobile Automation upgraded a leading cable manufacturer's AB25 extruder line — new motor, MCC, guarding and a modern PLC/HMI control system — a project of around $72k.
Designed around the network the line already ran
The upgrade was scoped from the machine itself.
- Extruder walked through with the site team to set what came out and stayed
- Drawings reviewed against the equipment installed
- New control system built onto the existing S7-1500 PLC and SEW drive network
- DC drive and thermocouple runs recorded before design began
MCC, HMI panel and guarding built before dispatch
Panel work was completed and proven in the workshop.
- Existing cabinet extended with a second enclosure
- Panels stripped for powder coating, then rebuilt with new gaskets
- Infill mounting plate carrying the earth and neutral bars, plus extra control duct
- Main isolator fitted into the drive enclosure
- HMI panel built to the schematics with pushbuttons, emergency stop, screen and vent
- Every connection tested against the drawings before dispatch
Line cut over to the new MCC
Existing services were labelled out and re-run to the new MCC.
- Heaters, fans, thermocouples, old HMI and drive supply labelled as they were disconnected
- Existing 300 mm² XLPE SDI mains pulled down to the new MCC on new NEMA 2 tray
- Separate runs for the motor, thermocouple, heater and fan cables
- Interposing relays interfaced the new panel into the existing machine
- Powder-coated guards, polycarbonate covers and tray and ladder covers fitted
Commissioned across drive, instruments and line interlocks
Commissioning ran from the motor through to the upstream machine.
- Motor and drive, I/O and PLC checks, wire-break checks and SEW drive I/O
- Spark test, pressure reading and laser feedback checked, laser wiring proven against its diagram
- Ramp-up and ramp-down sequence set in the PLC
- Fault holding the upstream Parma machine brakes traced in the PLC code and corrected
- Interlock stopping the extruder line when that machine stops confirmed with operators and the site engineer
The results
- AB25 extruder line running on a new motor, MCC and PLC/HMI control system
- Guarding, covers and new tray fitted across the upgraded equipment
- Line interlock with the upstream machine proven with site personnel