Our Project Execution Plan Was
Using the Acopos P3 allowed us to only need two drives versus previously requiring 4 drives for the machine, the Acopos P3 were both dual axis units, with each controlling two motors for movement.
Another key objective was improving machine flexibility and usability. Using B&R mapp Motion and mapp View technologies, we developed an advanced production sequencer that allows operators to create and manage multiple wire bending steps directly on the HMI. This enabled faster setup times, easier product changeovers, and significantly improved production efficiency.
All-New Units Installed
* B&R ACOPOS P3 Servo Drive System
* B&R PLC Control Platform
* Modern B&R mapp View HMI Interface
* New Electrical Control Panel
* Servo Motion Control Architecture
* External Encoder Feedback System
* Safety and Interlock Circuitry
* Production Sequencer and Recipe Management System
#Control Panel and Operator Interface
The original control system was completely removed and replaced with a modern industrial automation platform designed around reliability, maintainability, and ease of operation. The new HMI provides operators with a clean and intuitive interface for machine setup, diagnostics, manual jogging, recipe handling, and production sequencing.
The upgraded system allows for improved fault monitoring, simplified maintenance, and enhanced operator interaction compared to the legacy platform. With intergrate VPN for ease of technical support from anywhere.
The major challenge during this project was implementing highly accurate wire feed control through an external encoder system mounted via gearbox-driven wheel cogs. Precise wire feed measurement was critical for maintaining dimensional accuracy during complex bending sequences. To overcome this, we integrated an external encoder feedback system into the B&R ACOPOS P3 motion platform and developed custom compensation logic to ensure repeatable positioning and feed accuracy.
Client Feedback
The client was extremely satisfied with the transformation of the machine. The upgraded control system significantly improved reliability, accuracy, and production flexibility. Operators praised the intuitive mapp View interface and the ease of creating new production sequences directly from the HMI.
The implementation of the ACOPOS P3 motion system and advanced feed measurement technology resulted in far greater precision and consistency during production. Most importantly, the client now has a fully supportable and modern automation platform capable of meeting future manufacturing demands while dramatically reducing downtime and maintenance challenges.
Breakdown of the Upgrade Process
Assessment and Planning:
* Conducted a full evaluation of the existing PAVE HURON AXIS 6 machine
* Identified reusable mechanical components and obsolete control systems
* Collaborated with the client to understand production requirements and future scalability
Hardware Overhaul:
* Installed new B&R ACOPOS P3 servo drive systems
* Upgraded the machine control platform using B&R PLC technology
* Integrated modern industrial networking and motion control infrastructure
Motion Control Implementation
* Implemented B&R mapp Motion for coordinated multi-axis control
* Integrated external encoder feedback for high-precision wire feed measurement
* Tuned servo systems for stable and accurate machine performance
Software Implementation:
* Developed a modern operator interface using B&R mapp View
* Created a production sequencer for programmable step-based wire bending routines
* Added diagnostics, fault handling, manual setup screens, and production management functionality
Wiring Revamp:
* Completely rewired the machine and control panel
* Installed new safety systems and interlocks
* Improved maintainability and long-term reliability of the electrical infrastructure
Testing and Calibration:
* Conducted extensive feed accuracy testing and motion calibration
* Performed production validation under real operating conditions
* Optimised machine sequencing and operator workflow for production efficiency
