{"id":623,"date":"2021-06-23T13:02:09","date_gmt":"2021-06-23T13:02:09","guid":{"rendered":"http:\/\/www.wba.systems\/wba1\/?page_id=623"},"modified":"2022-04-28T19:31:45","modified_gmt":"2022-04-28T19:31:45","slug":"plastic-film","status":"publish","type":"page","link":"https:\/\/www.wba.systems\/wba\/automation\/projects\/plastic-film\/","title":{"rendered":"Plastic Film"},"content":{"rendered":"\n<p>A Plastic Film company purchased a used Alpine&nbsp; 5-Layer blown film extrusion line.&nbsp; Unfortunately, when the system was installed (after lengthy delays), the main PLC (Siemens S-545) was no longer operational.&nbsp; Although WBA could connect to the PLC, the memory fault could not cleared, and it could not be programmed.&nbsp;<\/p>\n\n\n\n<p>WBA upgraded the S-545 to a Siemens S7-1500.&nbsp; The system was originally programmed with the following:&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;<\/p>\n\n\n\n<ul class=\"wp-block-list\"><li>S7-1500 main processor<\/li><li>Six S7-300 blocks on profibus for control of the 5 extruders and die<\/li><li>One Wago IO block on profibus for control of the secondary nip roller<\/li><li>Communication to a Siemens S-5 plc which controlled the take-off system<\/li><li>Five Siemens Simoreg DC drives (on profibus) for extruders<\/li><li>Three Siemens Simovert AC drives (on profibus) for take-off and nip rolls<\/li><\/ul>\n\n\n\n<p>Later the upgrade was expanded to include removing the S-5 plc in the take-off system and replacing with an&nbsp; ET-200 block on profibus (incorporating the logic into the S7-1500) and replacing the Wago IO block with an ET-200 block.<\/p>\n\n\n\n<p>System had a Wonderware operator screen that interfaced to Alpine system and Foremost Plastic Pellet feed system.&nbsp; WBA upgraded this system to the latest version of Wonderware and a Windows-10 pc.<\/p>\n\n\n\n<p>In addition to the upgrade of the extrusion line, WBA assisted with startup of the PLC-5 based plastic pellet delivery system the feeds pellets to the extruders.<\/p>\n\n\n\n<figure class=\"wp-block-gallery has-nested-images columns-default is-cropped wp-block-gallery-1 is-layout-flex wp-block-gallery-is-layout-flex\">\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200911_121725889.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"728\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200911_121725889.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-728\"\/><\/a><figcaption>System from Ground Floor<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200408_105532751.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"737\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200408_105532751.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-737\"\/><\/a><figcaption>Die and Extruders<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200911_111335854.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"729\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200911_111335854.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-729\"\/><\/a><figcaption>Die and Cage<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20210429_102351593.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"717\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20210429_102351593.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-717\"\/><\/a><figcaption>Start of Film Bubble<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20210408_093107178.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"720\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20210408_093107178.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-720\"\/><\/a><figcaption>Film from Above<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20201001_150454948.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"721\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20201001_150454948.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-721\"\/><\/a><figcaption>1 of 6 Profibus Remote Boxes<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200911_124813716.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"723\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200911_124813716.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-723\"\/><\/a><figcaption>View from the Top<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200528_114507853.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"733\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200528_114507853.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-733\"\/><\/a><figcaption>Main Power Enclosuure<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200911_124659753.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"726\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200911_124659753.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-726\"\/><\/a><figcaption>Winder Control Panel<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200408_121836658.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"736\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200408_121836658.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-736\"\/><\/a><figcaption>Take-up S-5 before upgrade<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/07\/IMG_3163.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"1042\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/07\/IMG_3163.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-1042\"\/><\/a><figcaption>Take-up with ET-200 block<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/07\/IMG_20200408_121401829.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"1044\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/07\/IMG_20200408_121401829.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-1044\"\/><\/a><figcaption>Nip Enclosure before upgrade<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/07\/IMG_3164.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"1043\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/07\/IMG_3164.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-1043\"\/><\/a><figcaption>Nip Enclosure with ET-200 block<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200528_111133614.jpg?ssl=1\"><img data-recalc-dims=\"1\" decoding=\"async\" loading=\"lazy\" data-id=\"734\" src=\"https:\/\/i0.wp.com\/www.wba.systems\/wba\/wp-content\/uploads\/2021\/06\/IMG_20200528_111133614.jpg?w=750&#038;ssl=1\" alt=\"\" class=\"wp-image-734\"\/><\/a><figcaption>S7-200 for diameter sensors (replaced with ET-200 block0<\/figcaption><\/figure>\n<\/figure>\n","protected":false},"excerpt":{"rendered":"<p>A Plastic Film company purchased a used Alpine&nbsp; 5-Layer blown film extrusion line.&nbsp; Unfortunately, when the system was installed (after lengthy delays), the main PLC (Siemens S-545) was no longer operational.&nbsp; Although WBA could connect to the PLC, the memory fault could not cleared, and it could not be programmed.&nbsp; [&hellip;]<\/p>\n","protected":false},"author":2,"featured_media":720,"parent":613,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"page-templates\/template-fullwidth.php","meta":{"nf_dc_page":"","om_disable_all_campaigns":false,"footnotes":""},"categories":[5],"tags":[],"class_list":["post-623","page","type-page","status-publish","has-post-thumbnail","hentry","category-projects"],"jetpack_sharing_enabled":true,"_links":{"self":[{"href":"https:\/\/www.wba.systems\/wba\/wp-json\/wp\/v2\/pages\/623","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.wba.systems\/wba\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/www.wba.systems\/wba\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/www.wba.systems\/wba\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.wba.systems\/wba\/wp-json\/wp\/v2\/comments?post=623"}],"version-history":[{"count":5,"href":"https:\/\/www.wba.systems\/wba\/wp-json\/wp\/v2\/pages\/623\/revisions"}],"predecessor-version":[{"id":1792,"href":"https:\/\/www.wba.systems\/wba\/wp-json\/wp\/v2\/pages\/623\/revisions\/1792"}],"up":[{"embeddable":true,"href":"https:\/\/www.wba.systems\/wba\/wp-json\/wp\/v2\/pages\/613"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.wba.systems\/wba\/wp-json\/wp\/v2\/media\/720"}],"wp:attachment":[{"href":"https:\/\/www.wba.systems\/wba\/wp-json\/wp\/v2\/media?parent=623"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.wba.systems\/wba\/wp-json\/wp\/v2\/categories?post=623"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.wba.systems\/wba\/wp-json\/wp\/v2\/tags?post=623"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}