Modernising Line-up Operations With Automation

The Challenge Behind the Solution

Manufacturing environments demand both efficiency and safety yet these requirements often seem at odds. For Sull Systems, their lineup stations in Production Shops 1 & 2 presented exactly this dilemma. Operators faced increasing safety concerns, while production managers struggled with reliability issues and costly downtime. The existing control systems simply couldn’t deliver the monitoring precision and automation capabilities needed in a modern manufacturing environment.

The Critical Issues

Production was hampered by three fundamental challenges:

• Safety vulnerabilities during lateral movement of heavy workpieces
• Manual lineup inefficiencies creating bottlenecks and inconsistent results
• Limited monitoring capabilities preventing proactive maintenance

A Smarter Approach to Control

Rather than applying piecemeal fixes, Sull Systems took a comprehensive approach. Working closely with both safety experts and production staff, they developed an integrated control solution that addressed both safety and productivity simultaneously.

The solution centred around:

• Intelligent speed monitoring that protects without unnecessary interruptions
• Precision auto-lineup capabilities removing human error from critical alignments
• Integrated safety systems that meet industry standards without compromising productivity

Key System Components

Safe Speed Monitoring

• Pilz safety encoder and controller system
• Speed monitoring module
• Ethernet communication modules
• Visual and audible alarm indicators

Auto-Lineup System

• Laser Distance sensors for X/Y positioning
• ArmorBlock interface modules
• Rockwell PLC Control Logix
• HMI with graphic interface

How the System Functions

At its core, the new system brings together two critical capabilities Safe Speed Monitoring and Auto-Lineup into a unified control architecture:

Safe Speed Monitoring System

• Monitoring and Other Inputs: Pilz safety encoder HTL differential for measuring the speed of the Drive Roll. A selector switch and reset push button are included. Inputs are connected to a Pilz expansion input/output module.
• Controller: Pilz m B1 controller with a speed monitoring module.
• Relays and Outputs: Physical outputs from the relay module are connected to slave relays and valves. Diagnostic and process data are transmitted using a Pilz ethernet module. Audible/visual alarm is provided by a signal tower.

Auto-Lineup System

• Monitoring and Other Inputs: Position monitoring of the tables is achieved using Laser Distance analog sensors. There are two sensors per table to monitor the “X” (extend/retract) and “Y” (raise/lower) positions for Near, Middle, and Back Tables. Analog signals are converted to data on Ethernet IP using 2 x ArmorBlock interface modules with M12 connectors. The ArmorBlock also provides auxiliary power for the sensors. User operational inputs are provided as graphic push buttons on the HMI.
• Controller: The existing Rockwell PLC 1756-L63 Control Logix is used for logic and data processing.
• Outputs: Analog outputs for PWM Controllers are transmitted via the Ethernet module to 4-20 mA physical outputs. Digital outputs for Block valve control are transmitted via Ethernet module for Profibus enabled physical outputs. Audible/visual alarm is provided by a signal tower.

Key Technological Advantages

Safety Without Compromise

The system employs a dual-limit approach to speed monitoring, allowing normal operations to continue unimpeded while maintaining vigilance for potentially dangerous conditions. Visual and audible warnings alert operators before safety interventions become necessary.

Precision Through Automation

The calibration process uses multiple reference points to create a comprehensive positioning model. This allows the system to compensate for real-world variables that previously required operator experience and judgment.

Intelligent Integration

Rather than functioning as separate systems, the speed monitoring and auto-lineup capabilities work together through a unified PLC architecture. This integration means safety systems have complete situational awareness, avoiding unnecessary shutdowns while maintaining protection.

Measurable Improvements

The implementation has delivered substantial benefits:

• Enhanced operator safety through consistent speed monitoring
• Reduced setup time with automated positioning
• Improved product quality through more precise alignment
• Decreased downtime from better preventive diagnostics
• Simplified training requirements with automated procedures

Frequently Asked Questions

How does the safe speed monitoring system work?

Answer: The system uses Pilz safety encoders to precisely track workpiece movement speed. These connect through expansion I/O modules to the Pilz mB1 controller with dedicated speed monitoring functionality. The controller compares actual speeds against two preconfigured limits. When approaching the first limit, warnings activate through the signal tower to alert operators. If speed exceeds the critical safety threshold, the system initiates appropriate safety measures via slave relays and valves. All monitoring occurs in real-time with redundant verification to ensure reliability even if individual components fail.

What makes the auto-lineup system more effective than manual alignment?

Answer: The auto-lineup system achieves positioning accuracy within fractions of a millimetre well beyond what’s consistently possible with manual methods. It uses laser distance sensors that measure position in both X and Y axes simultaneously across all three tables (Near, Middle, and Back). The system converts these precise analog measurements to digital data via ArmorBlock interface modules, allowing the Rockwell PLC to maintain exact positioning control. The system also stores calibration data for different product specifications, eliminating the variability that comes with operator judgment. This results in both faster setup and more consistent product quality.

How does the system integrate with our existing equipment?

Answer: The control system uses standard industrial communication protocols (Ethernet IP, Profibus and Profinet), allowing it to interface with most existing PLCs and control systems. The hardware components are designed for retrofit installation on existing lineup stations, typically requiring minimal mechanical modifications. For facilities with older control architectures, we provide appropriate interface modules to ensure compatibility.

How adaptable is the system to different product types?

Answer: The system can store multiple product profiles, each with specific alignment parameters. When production changes to a different product type, operators simply select the appropriate profile from the HMI.

The Long-Term Impact

The Sull Systems Lineup Station project demonstrates how thoughtfully designed control systems can simultaneously address safety requirements and productivity goals. By approaching these traditionally separate concerns as interconnected aspects of the same system, the solution delivers improvements that would be impossible with isolated safety add-ons.

This project serves as a blueprint for how manufacturing facilities can modernise their operations without sacrificing either safety or efficiency proving that with the right approach, these goals can actually reinforce rather than compete with each other.acturing.