Project Description: Automation of a Second-Stage Tire Manufacturing Machine

This project encompasses the design, manufacturing, and programming of an electrical cabinet and control system for the automation of a second-stage tire manufacturing machine. The solution integrates advanced electrical engineering, automation technologies, and electro-pneumatic systems to ensure precise control, safety, and operational efficiency in the tire production process. The project leverages industry-standard software and hardware, including Eplan Electric P8, Eplan Pro Panel, and Rockwell Automation’s Studio 5000, to deliver a robust and reliable system tailored to the specific requirements of tire manufacturing.

1. Electrical Cabinet Manufacturing

The electrical cabinet is engineered to house and protect the control components essential for automating the tire manufacturing machine. Key design considerations include:

• Safety and Compliance: Adheres to industry standards (e.g., UL, IEC), protecting against dust, moisture, and temperature fluctuations.

• Durability and Accessibility: Built with high-quality materials for reliability and designed for easy installation and maintenance.

• Scalability: Supports future expansions to meet evolving operational needs.

2. Electrical Drawing for Automation with Eplan Electric P8

Using Eplan Electric P8, detailed electrical schematics are developed to serve as the foundation for the control system. These drawings include:

• Component Specifications: Details electrical components like safety relays, VFDs, sensors, and actuators.

• Wiring Diagrams: Accurate connections for assembly and troubleshooting.

• Automation Logic: Sequences for machine operations, including safety interlocks and pneumatic actuation.

• Compliance Documentation: Ensures adherence to regulatory standards.

3. 3D Panel Layout with Eplan Pro Panel

Eplan Pro Panel is utilized to create a 3D model of the panel layout, optimizing component arrangement within the electrical cabinet. Key features include:

• Space Optimization: Efficient placement for wiring and ventilation clearance.

• Thermal Management: Enhances heat dissipation to protect critical components.

• Collision Detection: Virtual validation to prevent assembly errors.

• Accessibility: Layout designed for ease of installation and maintenance.

4. Design and Programming of Allen Bradley ControlLogix with Studio 5000

The control system is powered by an Allen Bradley ControlLogix SLC, programmed using Rockwell Automation’s Studio 5000 software. This phase involves:

• System Architecture: Configures PLC hardware, I/O modules, and safety relays for tire manufacturing.

• Control Logic: Develops logic for motor control, sensor integration, and emergency shutdowns.

• Safety and Reliability: Implements fail-safes, alarms, and diagnostics for dependable performance.

• Documentation: Provides program details for maintenance and enhancements.

5. Design and Programming of Allen Bradley PanelView with Rockwell Automation software Factory Talk View

An Allen Bradley PanelView HMI is designed and programmed using Rockwell Automaton software Factory Talk View to provide operators with an intuitive interface. Key elements include:

• User-Friendly Interface: Displays real-time data like machine status and fault alerts.

• Real-Time Control: Integrates with PLC for operational control.

• Diagnostics: Offers troubleshooting tools for rapid issue resolution.

• Security: Features user authentication for secure access.

6. Electro-Pneumatic Cabinets

Electro-pneumatic cabinets manage the pneumatic systems integral to the tire manufacturing process. These cabinets house:

• Pneumatic Distributors: ASCO Numatics distributors for precise air flow control.

• I/O Modules: Point I/O modules for seamless PLC integration.

• Safety and Efficiency: Ensures reliable operation and minimal downtime.

Project Integration and Outcome

The project integrates all components into a fully automated system, thoroughly tested for seamless operation and compliance. The result delivers:

• Operational Efficiency: Optimized machine performance and tire quality.

• Safety: Robust safety features to protect operators and equipment.

• Ease of Use: Intuitive HMI and organized electro-pneumatic systems.

This project exemplifies precision and reliability, utilizing Eplan Electric P8, Eplan Pro Panel, Studio 5000 and Factory Talk View for a high-performing, scalable solution.