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Jennerjahn Realizes Time Savings Up To Two-thirds on New Control Platform Implementation

Three-drum surface slitter rewinder outfitted with Siemens hardware and software achieves Category 4 safety standard with space savings and more flexibility in design

Jennerjahn JLS-120, a popular 120” wide format slitter rewinder, capable of producing 400-foot rolls in less than 30 seconds, was customized using a total package of Siemens controls and software.  The robust frame on this machine makes it ideal for construction grade materials, such as house wrap, roofing and flooring underlayment, billboard vinyl and landscaping rolls.

Jennerjahn JLS-120, a popular 120” wide format slitter rewinder, capable of producing 400-foot rolls in less than 30 seconds, was customized using a total package of Siemens controls and software. The robust frame on this machine makes it ideal for construction grade materials, such as house wrap, roofing and flooring underlayment, billboard vinyl and landscaping rolls.

Jennerjahn, located in Matthews, Indiana, is a manufacturer of assorted lines of narrow and wide web slitter rewinders and custom machinery used by converters of point-of-sale cash register rolls, ATM rolls, lottery rolls and a variety of tape rolls, as well as a wide range of paper and other products, including laminating film, plotter paper, house wrap, landscaping products, vinyl billboard sheeting, flexible packages, box tape, roofing underlayment and other construction materials.  Founded in 1978, the company also provides customer solutions for roll handling and roll packaging equipment.  Today, Jennerjahn equipment can be found in markets worldwide.

On a recent job for a building products company in Australia, the Jennerjahn engineering team, led by Roger Vogel and Will Adams, was confronted with a unique set of requirements on a 120-inch wide, three-drum surface slitter rewinder, a variation of the company’s standard Model JLS-120, to be used to wind a variety of non-woven web materials, used in the construction industry.  The machine required five axes of motion control.  The JLS line features an unwind with pneumatic braking, a driven surface winder and driven lay-on roll.  The machine typically slits a web into multiple sections and the surface winder winds a small diameter roll to a precise length.

100_2078-1rtThe customer required a Category 4, SIL 3 safety system, with components to support a local 415VAC, three-phase electrical power supply.  As Jennerjahn senior controls engineer Will Adams explains, “We discussed the job with the applications engineering team at our local distributor and the decision was made to utilize a total package of Siemens hardware and control software, including Simatic PLC, Sinamics drives, HMI and a Profibus DP communications network.”  While Jennerjahn had utilized Siemens products in the past, this machine requirement was a particular challenge, owing to the safety requirements, in particular.  The builder was seeking a solution that would not require adding large amounts of relays and other hardware to meet the customer needs, plus the Jennerjahn team wanted to utilize the standard controls enclosures on the JLS-120 for this job.  Adams continues, “The integrated safety features on the Siemens S7-300 PLC, plus the ability to execute a position move within the drive and also have those drives operate within a wide voltage range allowed us to meet the Category 4 safety level for our customer.”  He further notes that the compact “bookend” design of the drives enabled Jennerjahn to use the standard enclosure on their machine.  Previous JLS machines used AC/AC drives for all drive requirements.  On this machine, there were three additional ancillary axes, so the use of the Siemens S120 booksize drive platform enabled the machine design to run all driven axes in a single drive.  The use of the integrated E-POS positioning block in the S120 drive system and a high-resolution sin/cos feedback on the surface winder permitted very precise roll lengths, as well, on this application.

100_2048-1rtIn addition, many of the diagnostic features on the drive software helped the builder’s team with troubleshooting and start-up issues.  Finally, the I/O configuration of the Siemens platform “…allowed us to keep our existing distributed I/O layout with minimal system redesign,” said Adams.

The Jennerjahn team estimates that the implementation of the Siemens controls platform on this machine was achieved with a start-up time savings up to two-thirds, the result of various factors in the relationship between this builder, the controls vendor and the local distributor.  Will Adams explains, “Siemens provided us design assistance to verify the sizing information and specify the required drive hardware.  Our local distributor then provided a complete bill of materials to us, which saved us a great amount of time, owing to our lack of detailed knowledge about the Siemens products.” Adams also notes his company received several days of onsite engineering support provided by the controls supplier to help with drive set-up, network troubleshooting and the integrated safety program modifications required on this machine build.

100_2111-1rtRoger Vogel, engineering manager for Jennerjahn, adds, “This project went very smoothly for us, because the relatively few problems we had were quickly handled by the folks from Siemens and our local distributor, both in the hardware and software areas, plus overall automation integration scenario.  The training class we were offered was very well run and provided our team the extra information needed to successfully program the machine.”

Since 1978, Jennerjahn has been a leading supplier to the converting industry and today provides an international partner to the industry, offering the most efficient solutions to customer needs on a wide variety of end uses.  As a full line machine and ancillary equipment manufacturer, the company maintains a showroom of assorted automated slitter and rewind machinery, so any potential application can be tested, free of charge, according to the company’s website.

For more information on this story, please contact:

JENNERJAHN MACHINE, INC.
901 Massachusetts Avenue
Matthews, IN 46957
Phone:  765-998-2733
Fax:  765-998-2468
Web:  www.jennerjahn.com
Email:  sales@jennerjahn.com
Attention:  Chris Jennerjahn, Roger Vogel or Will Adams

or

SIEMENS INDUSTRY, INC.
Drive Technologies — Motion Control
390 Kent Avenue
Elk Grove Village, IL  60007
Phone: 847-640-1595
Fax: 847-437-0784
Web:  www.usa.siemens.com/motioncontrol
Email:  SiemensMTBUMarCom.industry@siemens.com
Attention:  John Meyer, Manager, Marketing Communications

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Energy savings with “E-motion”

Servo-electric pump drive optimizes hydraulic presses — from a technical and energy efficiency perspective

The servo-electric pump control for presses, developed by Lasco Umformtechnik GmbH in Coburg, uses far less energy than conventional valve control systems, often well into the double-digit range, according to this press builder.

The servo-electric pump control for presses, developed by Lasco Umformtechnik GmbH in Coburg, uses far less energy than conventional valve control systems, often well into the double-digit range, according to this press builder.

A hydraulic pump directly coupled with a servomotor is an energy-efficient solution that delivers a highly dynamic performance with double-digit energy savings typical.  The press manufacturer Lasco uses this servo-electric pump drive for solid and sheet metal forming presses.  “This drive system provides us many performance advantages,” says Harald Barnickel, Head of the Electrical Engineering Department at Lasco Umformtechnik GmbH.

Harald Barnickel, Head of the Electrical Engineering Department at Lasco Umformtechnik: "The innovative servo technology that we have developed for hydraulic presses was previously not available on the market."

Harald Barnickel, Head of the Electrical Engineering Department at Lasco Umformtechnik:
“The innovative servo technology that we have developed for hydraulic presses was previously not available on the market.”

“Our new servo technology provides substantial energy savings for companies operating our presses,” says Harald Barnickel, Head of the Electrical Engineering Department at Lasco Umformtechnik GmbH, a machine tool builder in Coburg, Germany, in describing the significant advantages of this innovative forming press technology.  This well-known manufacturer of systems for solid forming and sheet metal forming produces screw presses, forging hammers, forging and cross wedge rolls, and even complete plants that are used by the building materials industry to produce sand-lime products.  When Lasco was first founded in 1863, the main focus was on the iron foundry.  However, just a few years later, it began producing water turbines, followed by forging machines in 1880. Since then, the company has concentrated on producing machines for forming technology, and has been active worldwide for many years.  “As a solution provider, we develop customized systems for optimized workpiece transport within the press as well as for feeding and removing workpieces,” Barnickel reports.  The company has a strong focus on continuous improvement in its processes and technology.  And the servo technology mentioned above is exactly this kind of technological milestone, as demonstrated through Lasco’s implementation in a recently delivered deep drawing press with a press force of 800 tons for up to 40 strokes per minute.

A fast controller at the core

At the core of this type of solution is a Simotics 1PH8 servomotor from Siemens, which directly drives the hydraulic pump.  This drive is controlled by the Sinamics S120 drive platform.  A Simotion D445 motion control system handles the complete path, velocity and position control of the axes —
the Simotion controller and Sinamics drive are both from the same manufacturer.  With a response time of 250 µs, up to 256 axes can be rapidly synchronized and precise axis motion and curve profiles are executed.  “The initial applications have demonstrated that this type of servo technology provides outstanding results,” says Barnickel.  This applies to the closed-loop control performance as well as to its energy efficiency and the application as a whole.

The challenge on the deep drawing press was to control the press force and press speed, based on a motion profile that could be set individually.  The hydraulic force and thus the press force can be adjusted at the servomotor by means of the torque.  The plunger speed is controlled by the motor speed and thus by the volumetric flow rate of the pump.  For the project described, axial reciprocating pumps with a fixed displacement per revolution were used.

Scalability of the pump systems is a significant advantage

Four such pump systems connected simultaneously for a maximum pressure of 250 bar supply the pressure line for the press stroke of the plunger; three additional pump systems are responsible for the return stroke of the press plunger. “The possibility of scaling, in other words adapting this kind of standard servo solution to the actual requirements, is another advantage of this new technology that certainly cannot be underestimated,” notes Barnickel.

The hydraulic oil tank of the deep drawing press holds about 2377 gallons (9,000 liters).  Because of the high flow rate of 16,000 l/min, filling valves are used for the fast downward motion of the plunger.  The servo pumps provide the required flow rate for the actual pressing operation, with a speed of up to 100 mm/s.  In the past, high-precision control valves with zero overlap were necessary to obtain the precise traversing profiles.  Today, this function is handled by the motion control system, in conjunction with the servo pumps.  Thanks to this new technology, the valve systems in the press can be reduced by up to 40 percent.  The remaining valve technology is mainly needed to comply with machine safety specifications.

Energy milestone

As a result of the new technology, expensive, traditional valve systems were eliminated, and energy efficiency has been significantly improved.  Electrical expert Barnickel knows this only too well.  “In the past, the large cooling systems for the hydraulic oil had to be installed before the first test run at Lasco.  But now, with servo technology, significantly smaller units can be used, and they are not required until the press is actually operational at the customer’s facility.”  One reason for this is that the oil is no longer forced through the narrow gaps at the control edges of the control valves, which means that these types of technology-related losses no longer occur in the first place.  The press manufacturer is seeing efficiency improvements well into the double-digit range depending on the application, significantly reducing users’ electricity costs, compared to older machines.

When comparing the new technology with very basic hydraulic presses using conventional technology, the amount of energy saved is certainly less than with presses equipped with complex control systems.  The energy-saving effect is especially apparent during the drawing operation, during which the drawing pressure is provided by a pump equipped with a servomotor, with the motor of the die cushion pump thereby operating as a generator.

Another advantage of the electrical system used here is that energy can actually be recovered when the hydraulic fluid decompresses.  This happens when the system is decompressed after the pressing operation and the main cylinder pressure must be reduced from 250 bar down to approximately 10 bar before the filling valve to the tank can be released.  This operation takes approximately 100 ms.  In the case of a compressibility of the hydraulic oil used of approximately 2.5 percent by volume, with a cylinder volume of approximately 800 liters of oil, the “spring energy” in the oil flows through the axial reciprocating pump and drives the servomotor.  This effect is amplified when the press mechanical system is relieved.  In this so-called generator or regenerative operation, the corresponding electrical energy is fed into the DC link of the S120 drive during each cycle.  “However, in addition to the energy recovered, the other advantage is that there are no additional power losses in the form of heat, as would be the case with conventional concepts,” Barnickel explains.

Straightforward optimization — and everything immediately documented

Although the Siemens Simotion controller has been specifically optimized to address motion control applications, Simotion can also control the complete system.  However, Lasco’s philosophy is to separate the various press tasks, and it therefore uses a separate PLC for the system control.  As a fail-safe control, this also addresses the safety technology requirements. Simotion can be programmed in various ways, for instance, with high-level-language, graphic programming, or Motion Control Chart (MCC) as well as a classic logic control.  The trace function with eight-channel plotter supports commissioning engineers and ensures detailed documentation of the press operation.  Control parameters are saved in the drive, which guarantees seamless documentation of the drive system.

The drive unit for the pump control consists of Simotics servomotors, Sinamics S120 drives and Simotion D445 motion control devices from Siemens.

The drive unit for the pump control consists of Simotics servomotors, Sinamics S120 drives and Simotion D445 motion control devices from Siemens.

Safety technology simply integrated

In addition, the fail-safe Simatic S7-319 F 3PN/DP PLC from Siemens, used here as the press system control, allows all safety technology to be implemented without any major additional expense.  The fail-safe signals are read via distributed Simatic ET200S I/O stations from the same manufacturer and transferred to the control via Profisafe.  This represents a simple yet complete solution for Lasco press engineer Harald Barnickel, who notes, “As a consequence, we obtain a clear machine structure.”

For instance, there are generally two monitored valves, which monitor the reduced traversing speed of the plunger, when setting up.  The new solution is far more precise, where the fail-safe S120 drive also monitors the reduced speed (Safely Limited Speed: SLS) as well as a safe stop (Safe Stop 1: SS1).

Simple parameterization through a seamless, integrated system

The press experts at Lasco also view the integrated, seamless nature of the Siemens systems as an additional benefit.  For example, the drive automatically identifies the servomotor and reads its parameters.  Another interesting feature of this servo solution is that the 1PH8 motors are available either as synchronous or asynchronous motors.  The application itself, or more specifically, the dynamic performance required, is the decisive element in selecting the appropriate motor type, according to Barnickel.

Both versions have the same mechanical mounting dimensions, the same wiring and the same encoder connection. Here, too, this state-of-the-art technology has some significant advantages.  For instance, instead of a typical 17-core cable, a single cable with RJ45 connector is sufficient.

And finally, this new drive concept for hydraulic presses, based on a servo-electric pump control, results in a significant overall improvement:  “In addition to the energy savings, its extremely precise controllability is far superior to that of a classic valve control,” says Harald Barnickel.  As he further noted, any defined motion profiles can be precisely implemented using this concept.

The motion control system has also proven itself to be extremely valuable in certain steps of the pressing process.  For instance, if the plunger moves to upper dead center, then the closed-loop position control in Simotion ensures that any leakages are compensated.  “A far higher precision is achieved when using servo technology than when using pure valve technology,” Barnickel summarizes.

Servo technology ensures dynamic performance of the press

The development of new servo technology for large hydraulic presses, based on the Simotion motion control system from Siemens, has already awakened significant interest among customers of Lasco Umformtechnik GmbH.  However, it is not only when building new machines that this dynamic company of 400 employees benefits from lower costs and improved quality; the drive concept described is also suitable for modernization and retrofit projects.

With the standard concept, comprising the Simotics 1PH8 servomotor, the Sinamics S120 drive platform and the motion control unit, Lasco Umformtechnik GmbH has clearly demonstrated that, when hydraulic presses are equipped with servo-electric pump drives instead of pure valve technology, the dynamic performance, precision and especially energy consumption on the press are improved.  This results in tangible press improvements that are decisive in the marketplace.  For Barnickel, it’s clear: “Anyone who addresses the challenges of press technology with E-motion (energy in motion) is creating innovation.”

For more information on this story, please contact:

Siemens Industry, Inc.
Drive Technologies — Motion Control Business
5300 Triangle Parkway, Suite 100
Norcross, GA  30092
Phone: 847-640-1595
Fax: 847-437-0784
Web:  www.usa.siemens.com/motioncontrol
Email:  SiemensMTBUMarCom.industry@siemens.com
Attention:  John Meyer, Manager, Marketing Communications

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Drilling Technical Services Develops Die Cut Thin Film Blank Accumulator with Siemens Motion Control

VR Series “cut and stack” accumulator utilizes leading-edge motion control products to efficiently transfer film blanks from point of cutting to positioning in counted stack

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Drilling Technical Services Inc. (DTS) in Milford, Ohio is machine builder specializing in the mid-width and narrow web press market. Its sister company, Pre-Owned Press & Parts Solutions, offers full reconfiguration engineering and remanufacturing services, plus full installation and commissioning on pre-owned presses

As a machine builder specializing in the design, engineering and system integration of narrow and mid-web label solutions as well as flexible packaging and folding carton machinery, Drilling Technical Services (DTS) of Milford, Ohio sees this global industry from many perspectives.  Much of the machinery and equipment solutions devised by DTS end up on the production lines of major label and filmic product producers worldwide.  Recently, company owner Joe Drilling and his team had one of those “light bulb moments” where a specific market need could be addressed by a better solution.

It involved the delicate world of thin film substrate processing and the need for a high-speed cut-and-stack solution.

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The VR Series “cut and stack” accumulator stacker machines for thin film in-mold label (IML) substrate processing features Siemens HMI, drives and servomotor technology to handle the delicate thin film substrates processed, with precision, accuracy, high speed and with fast changeover for the machine user

As Joe Drilling explains, “The primary challenge was to create a solution that took into consideration the unique environmental and material factors of each customer.  The materials our machines process are normally very thin film products that accumulate static quite easily.  Due to their structural instability, it always requires special transport

techniques to convey these products from the point of cutting to the point of positioning in a counted stack.”  Superior blank control throughout the process, converting blank shapes in multiple streams and integrating the equipment into continuous print cut processes or offline converting systems further complicated the challenges.

DTS team handles the design, engineering, build and line integration of the company’s various machine types for customers in the label, film, packaging and printing industries

DTS team handles the design, engineering, build and line integration of the company’s various machine types for customers in the label, film, packaging and printing industries

Further, the DTS team saw the industry trends toward smaller footprint equipment, greater energy savings, quick changeover and portability.  Collectively, these factors presented a daunting set of circumstances to Drilling and his design staff.

DTS realized the control scheme on the machine would be vital, so they turned to their longtime partner Siemens for assistance.  Through the integration of high-precision Sinamics drives and Simotion motion control, coupled with the complementary suite of Simotics servomotors and Simatic HMI touchscreen product, the VR Series of in-mold label (IML) accumulator stacker machines began to take shape.

Unique blank shapes are accumulated in 1, 2 or 3 streams on a small footprint machine requiring only 3’ x 4’ of floor space, capable of handling web widths from 13”-26”.  The VR Series machines from DTS provide end users with simple matrix separation, while diverting scrap at the process start-up or as a component in the overall quality inspection system.  The machines can create serialized groups through a “bottom up” stack format with total static control, so they can be utilized in a normal press room environment. DTS VR Series  IML Accumulator Pic 600 dpi

Noting the high-precision servo technology and motion control accuracy of the Siemens equipment onboard the VR Series, Drilling observed, “The axes communication and control are also extremely compact and this facilitated our designing a very portable machine with quick changeover capability, something our customers consistently demand.”

DTS further relies on the Siemens international sales and technical support teams, as this builder’s equipment is found in labeling, printing and converting plants worldwide.  Drilling notes his company has received a high level of consistent service, application engineering assistance and support from the Siemens personnel and affiliated contractors.

Joe Drilling has a pride in his company that’s classic American entrepreneur.  After years at a leading label machine builder, he founded DTS as a virtual engineering company specializing in the mechanical, electrical and process engineering of mid-width and narrow web printing, drying, converting, RFID and digital print equipment.  DTS has a particular emphasis on web transportation, die-cutting and laminating solutions.  As the installed base grew and in response to current market conditions, Drilling founded a second company in Milford, Pre-Owned Press & Parts Solution LLC (POPPS), specializing in the evaluation, reconfiguration, remanufacturing, sale, commissioning and servicing of pre-owned presses.

Another vital component of the business models at both DTS and POPPS is the engineering of energy recovery systems for containment of utility costs, an ongoing challenge in the printing and labeling industries.  The two companies primarily serve the needs of the flexible packaging, folding carton, tag and label, health and beauty, wine and beer, plus other label market segments.

For more information on this story, please contact:

DRILLING TECHNICAL SERVICES INC.
6062 Kells Lane
Milford, OH 45150
Phone:  513-831-2952
Fax:  513-831-4825
Web:  www.drillingtechservices.com
Email:  jdrilling@drillingtechservices.com
Attention:  Joe Drilling, President

or

SIEMENS INDUSTRY, INC.
Drive Technologies — Motion Control
390 Kent Avenue
Elk Grove Village, IL  60007
Phone: 847-640-1595
Fax: 847-437-0784
Web:  www.usa.siemens.com/motioncontrol
Email:  SiemensMTBUMarCom.industry@siemens.com
Attention:  John Meyer, Manager, Marketing Communications

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