timers and counters – for example, managing shift registers for the in-line process control to make sure we don’t have any faulty packs coming out of the finished delivery chute, which would otherwise involve more downtime or reduce batch quality.” The machine’s original motion control
commands have been replicated by Trio’s motion coordinator, combined with replication of all PLC controls which were added via IEC 61131-3 programming. Furthermore, set up of the controller and drives takes place within Trio’s Motion Perfect software and, with no special programming required, the application runs on the Trio controller’s standard functions. For Unette, it was an advantage that the Trio system is managed by a single software programme. “The software achieves what we were
previously attempting with several individual platforms. As the software interconnects the controller and servo, it’s more user-friendly and will hopefully save us a lot of time and cost in installation and commissioning future machines,” said Hudson. Of additional benefit,
Trio’s interconnected machine solution reduces the requirement for hard wiring as no cross- addressing is necessary between equipment from different vendors. In terms of programming, the new solution provides a considerable saving for Unette, which typically reprogrammes its
machines every few days depending on the requirement of its customers. And, as there will be less need to develop new code, this will enable faster development for each new application.
The pocket-sized Flex-6 Nano is just 147mm in height and is the width of an I/O slice, while the servo drives are among the most compact for their rating, enabling them to integrate easily into Unette’s existing machine. Furthermore, Trio’s products are also backwards compatible with support ongoing for 20 years-plus. This is a benefit for Unette, as Hudson explains: “We over-engineer machines to keep them flexible and for use in the field for a long time, so we
Unette now has three machines operating with
a full Trio solution and the company will begin to migrate its other machines. Unette will also implement additional controls such as pick-and- place for inserts into flexible packaging. While Unette is confident of long-term
efficiency gains in man-hours and reliability, a saving has already been made at the outset with the company reporting that the package is around 8% more economical than other vendors.
Flex-6 Nano
controllers, DX4 drives, and MX motors
need a guarantee of support and compatibility for legacy products, including backwards compatibility.”
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