CoilPro Machinery, Inc, located in Southington, CT, designs and manufactures custom-built machinery for all facets of the coil processing industry. CoilPro's production program includes slitters to process ferrous and non-ferrous materials with gauges as low as .001 in. and widths as wide as 48 in. and as narrow as 1/16 in.; rewinders for conventional or traverse wound spools, single strand, multi-strand, and other specialty equipment. CoilPro's experience is broad -- from one reel going into a press application, to multi-strand winding at speeds in excess of 1,000 fpm.
Doing business on an international scale, president Jeffrey Gagnon knew that standardizing the design and overall quality of the machine controls was critical to ensuring the highest level of customer service. He contacted Tony Pizzitola, president of Automated Industrial Controls (AIC), Plainville, CT, to help select a supplier to accomplish this goal. The search led them to Siemens Energy & Automation.
Both Gagnon and Pizzitola realized that an ongoing partnership with Siemens would provide quality standardized automation and electrical components built into every machine. "The results speak for themselves," Gagnon says.
According to Gagnon, standardizing on the Siemens TIA concept had numerous benefits. Some, including design consistency, process improvements, and superior product training and technical support, were immediately obvious; others were pleasant surprises. For example, he says, designing each machine is a unique experience. His relationship with Siemens helps him listen and adapt to his customers' needs.
"Our approach is similar to how we started our relationship with Siemens," Gagnon says. "They listened to what we needed and invested a lot of time learning our business; the same approach we have always had with our customers and their businesses. It is not unusual for Tony, someone from Siemens, and me to call on a customer and adapt a solution based on their feedback.
"Basically, we start with the slitter head itself," Gagnon continues. "We discuss the gauges, alloys, and tempers with the customer and what type of package they would like to wind up. We then work together to tailor a machine offering a complete turnkey operation to suit their needs."
Inevitably, each customer's goals include increasing productivity and quality by winding tighter coils and processing bigger packages, Gagnon says. By offering machine controls with a sophisticated software package, CoilPro has the automated portions of the process that allows the operator to repeat the same procedures time and time again.
CP30 Slitting Line
The latest product and most sophisticated CoilPro machine is the CP30 Slitting Line. According to Gagnon, the CP30 flawlessly processes coils at 600 ft per minute by incorporating automated processing technology not available from other machine builders. The CP30 processes coils up to 28 in. wide and has a maximum coil capacity of 6,000 lbs.
"This machine is the only one in the industry to offer automated core slipping and strip manipulation through a variable tension stand," Gagnon says. "Fifty-six tension zones monitor the rate of slippage on each coil. That is done very quickly over the Profibus network that works in conjunction with the CoilPro Air Drum." This line eliminates the inconsistency of manually operated machines of the past by reducing the risk of loose coils that require manual tightening. Strip tension is sensed and tension adjustments are made accordingly.
Pizzitola adds that by choosing to communicate over Profibus, he reduced wiring time by 40% compared to hardwired machines when fabricating the CP30 Slitting Line.
"We would have had to run more than 100 wires from the tension stand to the cabinet," he says. "By utilizing the Siemens architecture and Profibus we were able to reduce the run to a single connection. Also, by using Siemens ET200 Profibus I/O, either quick disconnect cabling or traditional potted cables may be used with the sensor application."
Totally Integrated Automation
The brain of the CP30 slitting machine is a Siemens SIMATIC® S7 315 DP PLC programmed with Step 7 Program Management environment. The PLC communicates at 12 Mbaud over the Profibus network. Three Siemens SE70 Master Series vector control drives connected by a common DC bus control a 10 HP bridal station motor, a 25 HP motor powering the slitter and a 45 HP motor on the rewind.
"The Step 7 Program controls all machine functions. For example, it assigns exact pressure to the hydraulic payoff with respect to coil size," Pizzitola says. "Core slipping has been a manual process requiring years of experience to produce consistent coils."
"In the past, manufacturers used regulators to make air pressure adjustments," Pizzitola says. "Imagine the potential human error as the finished coils got bigger and bigger. He would have to make adjustments on sheer instinct. The automation system on this machine takes the guesswork out of that equation."
The Step 7 Program automatically makes all required calculations so the individual components work in unison, producing flawless coils.
Simple Design, Easy Operation
The entire process is controlled via a Siemens MP 370 touch screen. However, Pizzitola was aware of operation realities when he programmed the software and designed the automation system.
"I made the machine as user friendly as I could," Pizzitola says. "You have to think like the operator and not like a programmer. It has to be very simple, with as little input as possible. Naturally, when you put different size coils on it, you have to do some inputting. But anything I can predetermine is in the program so the operator doesn't have to put it in."
CoilPro designed the CP30 balancing the use of new technology and operator intimidation while still maintaining simplicity. Pizzitola says that after only six parameter inputs, the machine automatically makes adjustments. At the same time, he says settings can be manipulated and scaling inputs altered at any time during the run.
"Our machines look like there is not a lot going on," Pizzitola says. "We don't want to scare people. At the same time there is a tremendous amount of automation built in. You may have an operator who has been running a machine for 30 years. He may not adjust well to the computer. Once he tries it he will see there is only one or two pages on the touch screen to learn."
CoilPro Vision Becomes Reality
Today, Gagnon's vision to be a leader in the coil processing industry is becoming reality. Working closely with AIC and Siemens, CoilPro builds turnkey products meeting each customer's needs. It has taken listening and adapting to customer needs to a new level, he says.
"The mechanical part of the machine is only as good as the electrical components and engineering that go into it," Gagnon says. "Wherever our machines go we know we can fall back on our relationships with AIC and Siemens. That helps us market our machines and gives our customers a great deal of comfort. And that is what grows our business."
