Project — machine automation
Rollformer automation upgrades.
Electrical controls, PLC programming and a custom operator interface brought together in one machine upgrade.
Electrical, PLC & Custom Operator Interface Upgrade
Highway Electrical completed a comprehensive automation upgrade for multiple existing rollforming machines, modernising the electrical controls, PLC system and operator interface to improve reliability, productivity and ease of operation.
The project combined electrical engineering, PLC programming, machine control and custom software development into a single integrated solution.
Project Overview
The existing rollformer required an upgrade to provide a more modern, reliable and user-friendly control system. Highway Electrical carried out the electrical and automation work, including upgrading the PLC controls and developing a customised operator interface tailored to the machine and production requirements.
The upgraded system gives operators greater control over production while providing improved visibility of machine operation, production batches and completed jobs.
Scope of Work
Electrical Upgrade
Upgrade of the machine electrical and control system to support the new automation platform and improve overall machine reliability.
PLC Upgrade & Programming
Development and implementation of the PLC control architecture, including machine sequencing, production control and integration with the operator interface.
Custom Operator Interface
A customised operator interface was developed specifically for the rollformers, giving operators a clear and intuitive way to control the machine and manage production.
Batching Function
Operators can create and manage production batches, allowing multiple jobs, quantities and production requirements to be organised before the machine is started.
Operation Logging
Machine operation and production events are logged, providing better visibility of machine activity and helping with production tracking and fault investigation.
Production Reporting
Production information can be recorded and reported, providing useful data on completed jobs, quantities and machine operation.
Remote Job Loading
The system includes the option for production jobs to be loaded remotely, reducing manual data entry at the machine and helping streamline the production workflow.
Integrated Machine Control
PLC, operator interface and production data functions were integrated into one coordinated control system designed around the customer's production process.
Custom Operator Interface
Rather than relying on a basic machine HMI, Highway Electrical developed a customised operator interface designed specifically around the way the rollformer is operated.
The interface provides operators with access to production jobs, batching functions, machine controls and operational information from a single screen.
This approach allows the control system to be designed around the production process rather than forcing the operator to work around the limitations of a standard interface.
Improved Production Management
The addition of batching, logging and reporting functions provides greater visibility over the rollforming process.
- Create and manage production batches
- Load multiple production jobs
- Record completed production
- Track machine operation
- Maintain production history
- Provide production reporting
- Reduce manual job entry at the machine
- Allow remote loading of production jobs
Benefits of the Upgrade
Improved Reliability
Modern electrical and PLC controls provide a more reliable platform for ongoing machine operation.
Better Operator Experience
A purpose-built operator interface makes production setup and machine operation clearer and easier for operators.
Reduced Manual Entry
Batching and remote job loading reduce repetitive manual entry and help improve production workflow.
Production Visibility
Logging and reporting provide useful information about machine operation and completed production.
Future Expandability
The upgraded control architecture provides a platform that can be expanded as production requirements change.
Integrated Solution
Electrical, PLC and software functions are combined into one coordinated machine control solution.
Machine Automation & Upgrade Capability
Highway Electrical provides complete machine automation and control system upgrades, from electrical design and control panel modifications through to PLC programming, custom operator interfaces and production software.
We can work with existing machinery to replace obsolete controls, improve machine functionality and develop customised automation solutions around the specific requirements of your production process.
Considering an Automation Upgrade?
Talk to Highway Electrical about upgrading or automating your existing machinery. We can develop a solution covering electrical controls, PLC, HMI, custom software and production integration.
Discuss Your Automation Project