The custom control panel built by Stegner is the brains behind the operation. The drives and controls inside dictate the entire MAD operation. There is a diverse use of products, showcasing our ability to integrate and program across several platforms. This control panel includes components from Bosch Rexroth, Allen Bradley, Siemens, and Murrelektronik. All of these components play critical roles in the MAD operation – each responsible for its own station and its functions. Their connectivity and reliability are unparalleled and allow us to control a complex automation solution with ease.

How it Works

The Palletizer Station is controlled by an IndraControl XM21 PLC, and three separate Cs Drives from Bosch Rexroth. The XM21 PLC has an on-board Sercos master with 350 µs cycle time. It has modular expansion options with extension and I/O modules. This PLC is designed for centralized and decentralized controller topologies. The IndraDrive Cs compact converters offer integrated safety technology, Ethernet-based communication, and a multi-encoder interface. This compact design is ideal for single-axis applications.

Bosch Rexroth XM21 PLC IndraDrive Cs drives

The Cap Removal Station is controlled by the SIMATIC CPU by Siemens, which controls two Bosch Rexroth Cs drives powering the station. The SIMATIC system from Siemens is compact and highly versatile. The use of a Siemens component demonstrates our flexibility in engineering and programming solutions.

Siemens SIMATIC CPU

The Main IndraControl XM22 from Bosch Rexroth is used for the Fill Station. The Fill Station is also controlled by IndraDrive M technology with a power supply and line filter for voltage controls from Bosch Rexroth. The XM22 is simple to integrate thanks to I/O integration. Users have the option to further expand the system with extension modules for communication or safety. The IndraDrive M drive system supports a power range from 15 kW to 120 kW with energy-saving line regeneration.

Bosch Rexroth IndraControl XM22 IndraDrive M

The Dispense Station has three stops – load, dispense, and unload. The Dispense Load and Unload Stations are controlled by the Main IndraControl XM22 PLC and five drives from Bosch Rexroth. An MTX micro Control 3 integrated with servo drives and an optional spindle controls the dispense station. These Bosch Rexroth components are CNC driven.

Bosch Rexroth IndraControl XM22

Allen Bradley compact logic controls two Bosch Rexroth Cs drives in the Cap Load Station. This further demonstrates our engineering and programming flexibility.

Bosch Rexroth IndraDrive Cs

The Main IndraDrive XM22 PLC from Bosch Rexroth also controls the Press Station along with discrete safety I/O modules that communicate via SERCOS to the PLC.

Bosch Rexroth IndraControl XM22

The MAD Unit has multiple power distribution sources. Siemens Contactors are used to supply 480VAC to drives while a Murrelektronik power supply is used for 24VDC. Murrelektronik products are also used as variable amperage 24VDC circuit breakers throughout the panel.

Power Distribution

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