Metalworking Projects

Our project team has gained extensive expertise in the design and execution of comprehensive metalworking projects.

CNC Pipe End Forming Machine

Pedrazolli Stern 50 Control System Upgrade

A Local South African company ran into a production issue when their machines’ PC software crashed, leaving them stuck with no means of continuing work. The Pedrazolli Stern 50 is the client’s main use for end tapering on pipes. We were commissioned with the task of re-engineering this ancient, 25-year-old Italian machine.

Applying our previous cost-efficiency strategy, we analysed the existing equipment we would be connecting to. This project only possessed solenoid valves and a couple of sensors that were to be kept. The entire panel, control system, and software were redone from scratch.

The challenge we faced with this machine was integrating third-party motion control devices with the B&R PLC during tool change. The X-Axis, based on hydraulic movement, is controlled via the B&R PLC. The Z and Y-AXIS, based on servo drive motion, are controlled by the Third-Party motion controller.

All-New Units Installed

Control Panel and Pedastal

Our Project Execution Plan Was

Design an electrical layout for the panel based on the required field modules
Remove all unnecessary and legacy systems not required for our new system, e.g. power supply, old relays, defective control unit.
Install and mount all relevant units for our new System, e.g. Main Control PLC, C60 HMI Panel, and various relays, contactors, servo drives, and motion PLC
Identifying Valves and corresponding cabling for proportional servo valves and coil valves.
After confirming all termination and wiring to be correct. We proceeded with doing Hydraulic and I/O testing.
Proceed with sequence programming and user testing to fault find bugs ( this part takes the longest as the software is being written from scratch and tested)
The last thing to ensure was implementing interlocks and testing of these to guarantee the safety of individuals and equipment

Client Feedback

The client was thrilled with the outcome! They expressed satisfaction with the increased efficiency and precision of the machine. The modernised interface made operation more intuitive, and they appreciated the significant reduction in downtime due to maintenance issues. Overall, they felt that the upgrade not only met but exceeded their expectations, enhancing their production capabilities and providing a competitive edge in their market.

Breakdown of the Upgrade Process

Assessment and Planning:

Conducted a thorough evaluation of the existing Pedrazzolli Stern 50.
Collaborated with the client to understand their specific needs and goals for the upgrade.

Hardware Overhaul:

Replaced outdated components with modern, high-performance hardware.
Upgraded the hydraulic system for the X-axis to enhance control and responsiveness.

Software Implementation:

Integrated a new B&R PLC and HMI for better user interface and automation capabilities.
Installed a third-party motion control device to optimise performance across all axes.

Wiring Revamp:

Completely rewired the machine to improve safety and reduce maintenance issues.
Ensured all components were seamlessly integrated for efficient operation.

Testing and Calibration:

Conducted extensive testing to ensure the precision and reliability of the upgraded machine.
Calibrated the system for optimal performance in various applications.