Omron-based machine controller has benefits, says Halifax Numerical Controls

The new control system offers complete integration of machine functions, an intuitive graphical operator interface, simple menu-based roll type selection, almost unlimited expandability to add new roll types and powerful integrated diagnostics. The first of the new HNC RG300 machines has been operating for several months at a customer site in Wales, and its benefits have proved so convincing that HNC has already received orders for a further machine to be used in the UK, and no fewer than four machines that will be used in the far east. Rubber-coated rollers are used extensively in the printing and coating industries and must be accurately ground with a profile to suit their application. For some applications, the profiles are parallel, but for the majority a precise convex or concave profile is needed. The machines handle rollers up to 5 m long, 600mm in diameter and weighing up to a quarter of a tonne. Halifax Numerical Controls has considerable experience in designing and manufacturing these machines, but when the company started development on its new RG300 machine, it was determined to come up with a product that would set new standards for versatility, convenience and productivity, thereby giving HNC and the RG300 a strong competitive edge in UK and world markets. HNC's engineers concluded that using a CNC system may not offer the most flexible and customisable platform for their machine. After further investigations and after detailed discussions with Omron, HNC engineers decided the best option would be to design a radically new control system, based on Omron products, which would allow them to produce a fully customisable solution. With the new control system, profiles for each type of roller are prepared off-line, and are loaded into the control system via a standard SD memory card. The operator then chooses the required recipe via a hand-held barcode scanner. The selected product is confirmed on the display, and the control system does the rest. This arrangement is straightforward, which means the risk of costly errors is almost eliminated, and it also requires no CNC experience on the part of the operator. In addition, the graphical display minimises the amount of text used in the operator interface, making it readily adaptable to international markets. In fact, HNC has programmed the interface so that the essential small amount of text can be displayed in any one of 16 languages, with instant switching between languages. In addition, the operator interface can be easily and inexpensively customised to suit specific user requirements. The HMI unit has also been programmed to provide powerful machine diagnostics and to log key machine operating parameters, both functions being facilitated by the unit's ability to access all major operating parameters in all of the control devices via the EtherCAT network. Says Mike Diskin, managing director of Halifax Numerical Controls: "The Omron control solution gives us everything we were looking for in terms of performance, versatility and reliability, and it's also very good value. In fact, compared with other control systems we investigated, it gives us much more functionality for our money. "Our new RG300 machine is attracting a lot of interest, both within the UK and worldwide, and much of that interest is because of how easy it is to operate, which, of course, is largely a function of the control system. Omron has made it possible for us to develop a powerful, flexible and cost-effective solution that our customers love, and that will grow with us as we further develop the capabilities of our machines in future."