Line producing inserts in disconnectors – Hager
Implementation of a comprehensive control system for an automated machine producing spacers in overcurrent circuit breakers at the Hager Tychy plant.
Client
Hager Tychy
Scope of cooperation
PLC programming, HMI, robotics, integration of vision and measurement systems
Implementation period
Q1 2021 (offline programming) – Q2 2021 (commissioning and acceptance)
Project languages
Polish
About the project
The project involved creating an advanced control system for a production machine tasked with the precise manufacture of spacers in overcurrent disconnectors. The implementation was carried out for the end customer Hager in Tychy. The objective was to automate the process, increase efficiency, and ensure high quality of the final product through the integration of modern industrial automation technologies.
Scope of work
As part of the AmiSter project, he was responsible for comprehensive programming of PLC controllers Siemens S7-1500 and the HMI interface Siemens TP1500 Comfort. A key element was also programming of robots Epson SCARA-type robots, as well as the integration of advanced Cognex and Keyence vision systems and measurement systems. All work was carried out in accordance with the control contractor’s internal standards, which ensured consistency and high quality of the implementation.
Key elements of the scope
1) PLC and HMI programming
Implementation of control logic on a Siemens S7-1500 PLC and creation of an intuitive Siemens TP1500 Comfort operator HMI.
2) Integration of the Weiss rotary table
Incorporation of the Weiss precision rotary table into the machine’s operating cycle, ensuring precise positioning of components.
3) Programming the FlexFactory feeder with the Epson SCARA robot
Software of the FlexFactory system comprising a vibratory feeder, a Cognex camera for component recognition, and programming of an Epson SCARA robot for precise loading of subassemblies.
4) Measurement and quality control systems
Implementation of Keyence GT2 displacement sensors to measure assembly correctness and of Cognex and Keyence IV2 vision inspection systems to verify product quality.
5) Press-in technology with Festo servo drives
Application of Festo servodrives for the implementation of a precise press-fitting process, crucial for the functionality of disconnectors.
Challenges of the project
The execution of the project involved the need to integrate many advanced and diverse automation systems in a short time. The challenge was to ensure the highest precision of assembly and the quality of the final product, as well as to optimize the machine cycle time, which required a meticulous approach to the programming and calibration of every element of the system.
Main challenges
Technologies and solutions used in the project
| PLC controller | Siemens S7-1500 |
| HMI panel | Siemens TP1500 Comfort |
| Robotics | Epson SCARA robot |
| Vision system | Cognex, Keyence IV2 |
| Measurement system | Keyence GT2 |
| Servo drives | Festo |
| Distributed I/O | MurrElektronik Cube67 |
| Transport drives | SEW MDX91, MC07 |
| Communication | ProfiNet |
| Mechanical subsystem | Weiss rotary table, FlexFactory feeder |
Effects and benefits for the client
Most important results
• Successful start-up and commissioning of an automated line for the production of spacers in overcurrent disconnectors.
• Significant increase in the precision and repeatability of the assembly process.
• Ensuring continuous product quality control at multiple stages of production thanks to integrated vision and measurement systems.
• Achievement of the target machine takt time, which resulted in an increase in production efficiency.
• Creation of a stable and reliable control system that is easy to operate and maintain.
Added value for the Hager factory
The implementation of an advanced automation system brought Hager measurable benefits, such as increased production efficiency, reduction of assembly errors, and the assurance of consistently high product quality. Investment in robotics and vision systems enables long-term optimization of operational costs and provides scalability and flexibility in adapting to future production needs.
Why do clients choose us for projects?
Our team, consisting of experienced PLC programmers and roboticists, has demonstrated comprehensive knowledge in the field of programming of TIA Portal controllers Siemens S7-1500 and the integration of various automation systems. We have documented experience working with SCARA robots, Cognex and Keyence vision systems, as well as in projects requiring integration of subsystems from multiple manufacturers. Thanks to this we were able to meet the high requirements of the Hager project, delivering a stable and efficient solution in a short time.
Summary
The project for the implementation of the control system of the machine producing spacers for overcurrent circuit breakers for Hager in Tychy was an example of the effective integration of advanced industrial automation technologies. Thanks to the experience and comprehensive approach of the AmiSter team, it was possible to create a highly precise and efficient system that significantly contributed to the optimization of the client’s production processes, confirming our ability to carry out complex and demanding engineering tasks.
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