Advancing manufacturing automation

AS THE manufacturing site grew, the movement of raw materials from the warehouse to the module assembly plant was handled manually. Operators were physically transporting materials between buildings via forklift trucks and internally across three separate levels. This process was not only time-consuming but also resource intensive. Given the complexity of interlinking different levels within the facility, a bespoke solution was essential for Nidec Drives.

Jamie Evans, warehouse and distribution manager at Nidec Drives spoke about the plan: “We conducted value stream mapping, and by taking an overview of production, preparation, and process, were able to formulate the plan for a conveyor and lift system which would move raw materials around the factory, where they needed to be, and when they needed to be.”

Identifying the right partner

Evans embarked on a mission to find the ideal vendor for implementing the latest advancements in automated warehouse solutions. Nidec Drives operates under the ‘Nidec Way,’ a business management principle created by Nidec's founder, Shigenobu Nagamori. This principle emphasises excellence through lean management strategies, such as Just in Time (JIT) inventory management. Continuous improvement, or ‘kaizen,’ is fundamental to Nidec’s operations, so Nidec Drives needed a partner who could design a solution that embodied these dynamic strategies.

“We invested significant time in researching the right supplier to collaborate with us on achieving the optimal solution. Through extensive dialogue and interaction with Invar, they emerged as the clear frontrunner,” commented Evans.

Engineering specialist Invar provides turnkey automation solutions specified to individual clients. Both Invar and Nidec Drives share core values of innovation and efficiency. Invar proposed a solution that was fully tailored to Nidec Drives’ needs and values, offering a highly experienced and expert team.

VSDs prove pivotal

One of the most notable features of Nidec Drives' UK manufacturing site is that, where possible, the automated machinery in use—from component store cranes to production equipment—runs on the very Control Techniques variable speed drives that Nidec Drives manufactures. The new conveyor and lift system would be no exception. Invar, being non-affiliated, selected only the best elements for the project. By combining teamwork, top-quality components, and incorporating Control Techniques variable speed drives, Invar successfully completed the project ahead of schedule and within budget.

Invar’s solution involved the implementation of a tote transportation system comprising approximately 300 metres of Interroll powered tote conveyor and three Nerak lifts, spread across three buildings. The conveyor system features two tiers for goods in/out and the main assembly area. Operators use screens at the infeed stations to select the tote’s destination.

In any building on the manufacturing site, the tote License Plate Number (LPN) is scanned, and the operator places the carton onto the powered conveyor, selecting the tote’s destination using the HMI screen. The tote is then transported to the first lift and directed to the operator station. Once the operator has completed their tasks, the process of scanning the LPN, choosing the destination, and dispatching the materials is repeated. The efficiency lies in the system's ability to operate on demand, halting completely between tote loads. This energy and cost-saving feature significantly reduces the unnecessary consumption of precious resources, and is expected to achieve a return on investment (ROI) in under a year.

Leveraging Control Techniques products

Integral to the efficient stop/start nature of this system are the Control Techniques drives. For this project, two types of drives were utilised: three Unidrives, and eleven Digitax HD M750.

The Control Techniques Unidrive was selected for the lifts within the system. Unidrive offers exceptional control stability and bandwidth for all industrial motor types, with the M702 variant featuring onboard Ethernet and dual STO inputs.

Several option modules were fitted to the Unidrive. The SI-I/O Interface Module provided additional input and output connections. The SI-Universal Encoder Module, which ensures positional accuracy by connecting to a rotary encoder on the motor, was also added. This module checks if the encoder’s value matches that of a second encoder measuring position with a laser; if the values align, the Programmable Logic Controller (PLC) allows the drive to run; if not, the system’s brakes are applied.

Nidec engineers also utilised the PTi210 Easy Motion Controller. With this module there is no need for software development; it was simply plugged into the drive, then connected through PowerTools Studio software, enabling the creation of quick, simple, and repeatable routines which the Unidrives in the conveyor executes repeatedly. The PTi210 is compatible with both Unidrive and Digitax HD M750 drives.

For single axis motion with complex controls such as the conveyor, the PTi210 and Power Tools software package is a cost-effective way to provide simple, fast, and effective motion control. Users of all skill levels are able to configure, programme, select functions, and set up parameters; expediating the configuration, management, and long term maintenance of the conveyor.

Finally, the KI-Keypad was installed, allowing users to adjust drive parameters while displaying key information, such as current draw, RPM, or faults.

The Control Techniques Digitax HD M750 servo drive series complements the Unidrive range by providing maximum servo performance in a compact package. Digitax HD M750 is optimised for high-dynamic applications, offering flexibility in both standalone and modular configurations. This drive delivers full servo control, plus open-loop permanent magnet motor and induction motor control, across four functionality levels: EtherCAT, MCI machine control, Ethernet, and the flexible Base servo drive.

As a full machine control solution, the Unidrive works in harmony with three Leroy-Somer IMfinity 3-phase induction motors; one on each lift of the conveyor. Provided by Nidec ACIM, IMfinity motors reach premium efficiency up to IE4; maximising energy savings, enhancing performance, and optimising the productivity of the lifts. The robust design of the IMfinity range of Leroy-Somer motors ensures guaranteed performance and reduced cost of maintenance. To work seamlessly with the Unidrive, the IMfinity motors have winding protection as standard, thermal reserve for maintaining the rated torque over an extended speed range, and adaption of the metal support plate to reduce electromagnetic noise.

Sue Clark is global marketing communications manager at Nidec Drives

www.ControlTechniques.com