search.noResults

search.searching

saml.title
dataCollection.invalidEmail
note.createNoteMessage

search.noResults

search.searching

orderForm.title

orderForm.productCode
orderForm.description
orderForm.quantity
orderForm.itemPrice
orderForm.price
orderForm.totalPrice
orderForm.deliveryDetails.billingAddress
orderForm.deliveryDetails.deliveryAddress
orderForm.noItems
FEATURE


SPRINGS & SHOCK ABSORBERS Rather than replacing


its forming machine, a spring manufacturer took a retrofit


approach, enabling it to boost spring manufacturing


productivity by up to 50%. Delta explains how


S


prings are used in a huge range of products – from cars and home appliances, to beds and even doors.


However, the equipment used to bend, twist and form the wire to make tension, torsion and compression springs requires significant investment; and it needs to be capable of manufacturing these essential components in a productive and effective manner. So, if the spring former is showing signs of


ageing, retrofitting a CNC-controlled system could be an option. However, although retrofitting allows the bulk of the machine to be re-used it can be difficult to predict possible challenges; plus, the new retrofitted version needs to be able to offer benefits such as flexibility, speed and an enhanced user interface. Recently, a customer of Delta which had


around 60 spring formers spread across three manufacturing sites, faced this issue.


A RETROFIT SOLUTION Following discussions with Delta’s field application engineer Enric Tamarit and his team, together with a system integrator with mechanical engineering expertise, the spring manufacturer decided to go with the retrofitting approach. The new design features the AX-864E, a


CODESYS-basedmotion controller that is ideal for complex control applications. The compact, fan-less design, built around an Intel x86 CPU, ensured robustmounting coupled with support


FORMING AN


EFFICIENT WAY TO MANUFACTURE SPRINGS


for EtherCAT to control the selected drives. The unit also features an HDMI display port, gigabit LAN, four USB interfaces, a connector for RS-485/422 and a differential input motor encoder. Eight GPIOs provide NPN (sink) or PNP (source) control or input signals dependent on the model chosen. A watchdog timer, configurable through the BIOS, ensures the system automatically resets in the event of abnormal operation. In addition, a range of security features, including BIOS passwords and Delta’s PAC Tool for restricting writes to the integrated solid-state drive, are also included. Thanks to its support for CODESYS, an industry-standard IEC 61131-3 PLC language, the control system software was rapidly iterated to optimise the implementation. The wire forming was realised with ECMA


Series servomotors.With their state-of-the-art design, these provide a high torque-to-size ratio, low flux loss, and deliver low cogging suited to the smooth motion control required for spring manufacture. They could also be adapted to different spring-forming equipment needs thanks to a range of shaft options and encoders. Coupled with ASDA-A2 Series servo drives, connected via high-speed EtherCAT, simultaneous control of the servo motors was ensured. The characteristics needed for the retrofitted design were easily achieved thanks to the available high precision control, with a 1kHz frequency response and 1ms settling times, and superlative vibration suppression. Programmable positioningmodes


LATERAL SPRING PLUNGERS FOR HARSH CONDITIONS


Using a one-piece plastic spring body design, norelem’s lateral spring plungers are suited to harsh operating conditions such as painting or sandblasting. There are three designs available, which differ in terms of spring force; and a total of 42 designs with diameters of 6-16mm. Lateral spring plungers are used wherever workpieces and components


must be fixed or positioned to then process themfurther. They are often used, for example, in plant andmechanical engineering, and in the packaging, automotive or aerospace industries.


The components are available in threemain types – characterised by a light,mediumand strong


spring force. For the pins on the plungers, users can choose between hardened and burnished steel, stainless-steel and plastic (thermoplastic). Along with the higher resistance to swarf and drag out, the new lateral spring plungers are temperature resistant up to +100˚C.


norelem 3 DESIGN SOLUTIONS DECEMBER/JANUARY 2022 0 www.norelem.co.uk


(Pr Mode) also allow up to 64 internal position settings, supporting continuous motion control. Of additional benefit, the new design features


an improved user interface, allowing operators to configure the desired spring froma choice of recipes.With its 7in colour TFT display, the DOP- H07 Series provided the flexibility needed for this application. This IP55 rated handheld device weighs just 750g and includes an emergency stop button together with a hook for convenient storage when no longer in use. Connected to the AX-864E via a TCP Modbus,


the handheld display allows simultaneous configuration of the spring former while overseeing the actions executed by the servos. Delta’s DOPSoft configuration software enables visually appealing, clear, and easy-to- use interfaces inmultiple languages, ensuring simplicity for users. Simulation of the production process was also implemented, saving time and resources before committing tomanufacturing.


IMPROVED PERFORMANCE The new electronic CAM spring former design has improved the operating experience, with the ability to switch between the manufacture of different spring types simplified thanks to the user-friendly, recipe-style, selection offered by the human-machine interface (HMI). Added to this, new recipes can be easily developed by extending and modifying existing designs as and when required. Efficiency was a further benefit of the solution.


Previously it took a day tomake tooling changes tomanufacture a different spring. This has been reduced to half a day. In addition, productivity has been improved by 50% in most cases as the most straightforward spring designs can now be manufactured at double the previous rate. Although the initial retrofit has taken around


a year of close cooperation and work to complete, the results have been so impressive that the customer has decided to continue upgrading further spring formers. Because a CODESYS-capable motion controller was chosen, coupled with Delta’s easy-to-integrate HMI, servo drives, and servos, this approach will continue to be a cost-effective and reliable alternative to machine replacement.


Delta https://www.delta-emea.com/en-GB/index


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54