Case Study: Tube Forming Machine
The tube forming machine takes long lengths of stainless steel tubes, cuts them to length and also profiles the them. The machine has to handle tubes of many different diameters and wall thicknesses, it also has to be able to profile the tubes into an infinite number of shapes.
The machine was developed in the USA over ten years ago and has served the company well, however, there have increasingly been some reliability issues. The control system was difficult to operate, constantly crashed, and could not be programmed with the quantity of profiles required. Programming of the system was something of a 'Black Art', effectively undocumented and did not use real world units. I replaced the under powered stepper motor system with dc servo motors and a motion controller with integrated HMI. A gearhead was also installed to better match the load to the motor. The outcome is an extremely repeatable system that is both easy to program and to operate. The customer, an international manufacturer of heater cartridges is pleased enough to order two more machines to be upgraded.
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