Synopsis of Compact Crossbar Transfer Press Controls and LSV (Line Supervisor Software) Project

Situation: A German press OEM received a contract from one of the Big 3 automotive manufacturers to design, supply, and install four (4) identical Compact Crossbar Press Lines for North American production facilities. Press Description: The Compact Crossbar Press Lines each consist of a Front of Line (FOL) system, 6-Slice Partitioned Press systems, Modular Transfer Units (MTUs), End of Line (EOL) system, and Cushion System. Requirement: A Functional Specification (FS) to describe in detail each piece of equipment and its functionality and operation, complete with 1,000+ HMI prototype screens; describe how the controls worked, including all automatic and manual functions, as well as operator displays required for running equipment. The FS "blueprint" provided designers and developers with the foundation for proceeding with the detailed technical development.

Brock Solutions' Role: Develop a complete Functional Specification "blueprint" document, Line Supervisor software, and I/O simulator to test the 10,000 I/O system prior to site installation and commissioning. Main Technology Components: Allen-Bradley ControlLogix PLCs, Siemens’ hardware for field I/O, VersaView HMIs, Allen Bradley FlexLogix hardware, Rexroth MX4 NC, Beckhoff soft PLC system, Roland UDK 10/110 hardware, ControlNet, DeviceNet, Ethernet, and Line Supervisor (LSV) software.

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