Implementing the Bellybox Control System for Pipe Alignment Operations

The Challenge Behind the Solution

A major manufacturing facility faced a significant challenge in aligning pipes efficiently during production operations. The existing process required two operators to communicate continuously, which often led to errors, reduced production output, and costly downtime. The dilemma was clear: how to streamline operations without compromising safety and accuracy in a demanding industrial environment.

The Critical Issues

Production was hampered by three fundamental challenges:

• Communication Errors: Frequent miscommunications between operators led to alignment errors and rework
• Reduced Output: Errors and downtime significantly impacted production efficiency and throughput
• Safety Concerns: The manual process posed safety risks, especially during unexpected movements or equipment failures

A Smarter Approach to Control

Rather than applying piecemeal fixes, we took a comprehensive approach to introduce the Bellybox Control System, which allows a single operator to manage the alignment process directly from the machine. This solution was developed in close collaboration with the production team to ensure it met their specific operational requirements.

Core Solution Elements:

• Integration of the Bellybox Control System with existing PLC and HMI systems
• Implementation of comprehensive safety measures to mitigate operational risks
• Comprehensive training programme for operators

Key System Components

Control Systems:

• BB-Rx1: Bellybox Receiver
• PS-U4: Control Panel Safety Relay

PLCs and Control Hardware:

Existing Equipment:

• PLC: 1756-L63 CPU (Control Logix)
• HMI: Proface
• IO: Flex IO and IFM ASi

New Equipment:

• Bellybox: Hetronic
• Safety Relay: Guardmaster 440C
• Safety Relays/Contactors: Omron GS7

Pricing Information:

• Components purchased: £10,000
• Labour costs: £5,000

Additional Control Components:

• Reset pushbutton for system reset
• Bellybox power switch
• 6-position configurable selector switch for various controls
• Emergency stop pushbutton
• LED display for system status
• Line up roller joysticks (Roller 2 and Roller 3)
• Communications and battery status indicators
• Configurable joystick and switches for various control configurations
• Slow/Fast selector switch for speed mode selection
• Auto-line up switch for automated alignment function
• Hardwired control plug for backup control
• Constant torque enable pushbuttons

How the System Functions

Emergency Stop Control Panel:

• Task: Stopping the machine during hazardous events
• Description: Activation of the emergency stop pushbutton immediately removes power from the machine actuators. A deliberate reset sequence is required to restart the machine, ensuring operator safety

Bellybox Controls:

• General Description: The Bellybox allows operators to control line-up rollers and other functions directly from their optimal viewing position
• Enabling the Bellybox: Involves checking the emergency stop status, switching on the Bellybox, and establishing secure communication with the PLC
• Disabling the Bellybox: Requires returning the enable key to the control panel and properly shutting down the Bellybox system

Safety and Speed Controls:

• Battery State of Charge: Continuous monitoring and indication of battery level to prevent unexpected shutdowns
• Speed Control: Automatically restricts maximum speed to 20% when Slow/Fast selector switch is set to slow mode
• Dual Channel Safety: Ensures redundancy and reliability in all safety-critical functions

Key Technological Advantages

Enhanced Safety: The system employs multiple layers of safety protection, including immediate emergency stop functionality that removes power instantly to prevent accidents. Dual channel safety architecture ensures redundancy and reliability, meaning the system maintains protection even if individual components fail.

Operational Efficiency: Single operator control eliminates the communication bottleneck that previously required coordination between two operators. The configurable joystick system allows for precise control of various machine functions, whilst the auto-line up feature can handle routine alignments automatically.

Intelligent Integration: Rather than functioning as a separate system, the Bellybox integrates directly with existing PLC and HMI systems via EthernetIP communication. This integration means operators maintain full situational awareness whilst gaining enhanced control capabilities.

Frequently Asked Questions

How does the Bellybox improve safety compared to manual operations?

The Bellybox integrates with existing emergency stop systems and includes dual-channel safety features throughout its architecture. This ensures that any failure results in a fail-safe scenario, significantly reducing the risk of accidents. The system continuously monitors communication status, battery levels, and operator inputs. If any anomaly is detected, the system automatically initiates safe shutdown procedures. Additionally, the emergency stop function provides immediate power removal from all machine actuators, whilst the speed control system prevents operators from inadvertently exceeding safe operating speeds.

What training is required for operators to use the Bellybox system effectively?

Operators undergo a comprehensive training programme that covers the use of the Bellybox controls, emergency procedures, routine maintenance, and troubleshooting. The training includes hands-on sessions with the actual equipment, safety protocol reviews, and competency assessments. This ensures operators are fully equipped to handle both normal operations and emergency situations. The training typically takes 2-3 days and includes both theoretical understanding and practical application.

How does the Bellybox integrate with existing control systems?

The Bellybox communicates with existing PLC and HMI systems via EthernetIP protocol, ensuring direct integration without requiring major modifications to current control architecture. The system uses standard industrial communication protocols, allowing it to interface with most existing PLCs and control systems. All control and safety functions remain synchronised, and the HMI displays continue to provide operators with comprehensive system status information.

What ongoing maintenance does the Bellybox system require?

The system requires routine battery monitoring and periodic charging cycles. Visual inspections of the control housing and joysticks should be performed regularly. Communication system diagnostics are built into the system and alert operators to any issues. Annual calibration checks ensure continued accuracy of all control functions. The robust industrial design minimises maintenance requirements whilst maximising operational availability.

The Long-Term Impact

The implementation of the Bellybox Control System demonstrates how thoughtfully designed control solutions can simultaneously address safety requirements and productivity goals. By approaching operator communication challenges and safety concerns as interconnected aspects of the same system, the solution delivers improvements that would be impossible with isolated upgrades.

This project serves as a blueprint for how manufacturing facilities can modernise their pipe alignment operations without sacrificing either safety or efficiency, proving that with the right approach, these goals can actually reinforce rather than compete with each other. The success of this implementation has established new operational standards and serves as a model for future control system innovations in similar industrial applications.