Project L

Esteve Production Line Control System Upgrade

Project Overview 

Custom Controls has proposed an upgrade to an Esteve production line. The work addresses fluctuating load cell readings, adds servo control to the rotary valves for very slow operation, and replaces the existing CJ1W PLC and operator control equipment with an Omron Sysmac-based system. The proposal also includes new PCs, PcVue software and an SMS alarm messaging system.

The project requires the existing control software to be rewritten manually in Sysmac Studio. The proposed hardware, software and control panels will be assembled and tested in the workshop before an agreed site shutdown for installation and commissioning.

Project objectives

Stabilize weighing measurements with new load cell input hardware; the proposed controller hardware has been tested successfully on site.

Fit servo motors and associated gearboxes or adaptors to provide fine, low-speed control of the rotary valves.

Replace the legacy PLC arrangement with an NX5-based architecture, including safety control and capacity for up to 16 servo axes.

Provide a new 15-inch machine HMI with recipe handling and USB-based recipe updates, keeping the layout familiar to operators where practicable.

Refresh supervisory monitoring and support through PcVue, two new PCs, Alert alarm messaging and a reconfigured secure Ewon remote connection.

system Development and integration

The engineering team produced electrical drawings, schematics, parts lists and cable schedules, then assembled the control panels and equipment at its workshop. The PLC application was rewritten for Sysmac Studio because the proposal identifies no direct conversion utility. Servo drives and I/O nodes were configured, and the software ran and simulated with the hardware before the planned shutdown.

During the site phase, the team removed the existing motors and cables, installed and connected the new components, and completed programming, testing and commissioning on the production line. The HMI screen format will be agreed with the client, with the aim of matching the existing operating approach as closely as possible. The system was specified for a stand-alone network, with remote access through the secure Ewon connection.

system features and enhancements

Controller, safety and weighing

The Omron NX5 modular controller combines control, information and safety functions. The selected main CPU supports up to 16 servo axes, leaving room for additional axes if required later. The proposal identifies a main rack to replace the CJ1W PLC and a load cell rack with main and safety CPUs.

The NX-series load cell input unit offers sampling as fast as 125 microseconds, digital filtering and sensor disconnection checking. These capabilities support the aim of more stable and accurate weighing values.

Motion and operator interface

Omron 1S servo motors and drives will control the rotary valves. The proposed motor family includes high-resolution encoders and EtherCAT connectivity. A replacement 15-inch Omron NA series HMI will provide machine-level visualization and recipe handling, with recipes updateable from a USB drive.

Supervisory and alarm systems

The proposal includes the latest PcVue version, two new PCs using existing monitors, and an Alert SMS messaging system. The existing Ewon installation will be reconfigured for secure remote support.

conclusion

The proposed upgrade brings together stable load cell measurements, finer valve control, a new Sysmac PLC and HMI environment, and refreshed supervisory and alarm tools. Workshop assembly and testing are intended to reduce implementation risk before the agreed site shutdown. Final performance and acceptance will depend on successful site commissioning and validation against the existing process requirements.