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Addison builds benders with Hayes controls

Edited by the Engineeringtalk editorial team May 16, 2002

Addison Tube Forming has used PC-based control products from Hayes Control Systems to equip its latest range of tube bending machines.

PC-based control products from Hayes Control Systems have made it possible for tube-forming expert, Addison Tube Forming, to equip its latest range of tube bending machines with control systems which combine versatility, dependability and effective future-proofing with outstanding cost-effectiveness.

At the heart of the new control system is a PC equipped with a flat panel display, running Beckhoff TwinCAT NC-PTP software which, in the UK, is supplied and supported exclusively by Hayes Control Systems.

This innovative software package allows standard PC hardware to function as a powerful programmable controller and, simultaneously, as a high-performance motion control system.

The installation also includes a Profibus DP network which is implemented with Beckhoff protocol-independent fieldbus products.

Additional connectivity is provided by a Beckhoff Lightbus fieldbus system which is based on the use of low-cost optical fibre connections, and is, therefore, immune to the effects of even high levels of electrical interference.

"We looked at many possible control solutions before settling on TwinCAT and the other Beckhoff products", said Bill Watson, Controls Manager at Addison Tube Forming.

"Nearly all of them, however, would have required us to use a PLC and a separate NC system.

With TwinCAT, however, we could combine these functions in a standard PC, thereby making big cost savings.

In addition, having the PLC and NC functions running on the same machine simplified both the design of the control system and the programming".

Addison's machines are used in a wide range of applications, from the manufacture of car exhaust systems to the production of structural assemblies and air conditioning components.

The motion control systems in current machines must handle up to 21 axes simultaneously, and this number is expected to increase in future models.

The machines also use a large number of digital and analogue inputs and outputs.

"The TwinCAT solution easily met these requirements", continued Watson, "and also made life easier by allowing us to select the best type of feedback sensor for each axis, rather than being limited to just one type.

In addition, the new control system is very easy to update in the field, which is important to our customers and to us, as it means that they can benefit from our latest developments without inconvenience or high costs".

Addison's engineers found TwinCAT, which uses standard IEC61131-3 compliant programming languages, was easy to program once they had surmounted a short initial learning curve.

They also found the open communication structure offered by the equipment to be a useful benefit.

Installation and commissioning of the first machine proceeded smoothly, and the task of taking the design from the design office to the finished machine was remarkably problem-free.

The integration and debugging tools provided, as standard, in the TwinCAT software package greatly assisted with the commissioning process.

The Addison team also made use of Hayes Control Systems' support services, including the company's training courses, support desk, and on-site support options.

All of these were found to be well suited to users' needs, and to effectively complement the innovative product range.

As a result of its positive experience with Beckhoff products and systems supplied by Hayes Control Systems, Addison Tube Forming is now planning to increase the range of machines on which they are used.

(This was Engineeringtalk's Top Story on 15 May 2002).