Machine Builds

At best, Control System Design Engineers are involved in Mechanical & Machine Build processes at Design Board stage for optimal outcomes. NEW CASE STUDY: PLUG & PLAY.

Plug & Play

Dancer, Torque, Lazy Loops

What am I reading? Is it about dancing, instrumentation, or knitting?
This case study is about an exceptionally creative development by long-term project partners who are very experienced machine builders with in-depth mechanical expertise, providing bespoke, effective, and reliable machines worldwide.
For this machine, whether it’s Winding or Unwinding, Overwinding or Underwinding, to achieve the desired parameters on demand, imagine winding and shifting pathways and connections, with a versatile Winder slotting in and out where required to be a Plug & Play hero on the factory floor.

Plug & Play

During the running of the machine and due to a requirement for autonomous operation, a complex method of calculating the response of the unwind/rewind shaft in relation to the:
  • Dancer Position,
  • Motor Torque, and
  • Lazy Loop Position

has to be carried out at all times.

This functionality relies on other parameters being set to allow the machine to calculate the correct response. This includes:
  • Material Density, and
  • Material Width & Diameter
to calculate the roll inertia.
Using the calculated roll diameter and inertia information, a PID control loop is varied with:
  • Roll Diameter, and
  • Speed
to maintain the dancer in the central running position. This image illustrates that material wound onto rolls for industrial use also includes metal sheets.

Plug & Play

PID Parameters

PID stands for Proportional, Integral, and Derivative.

It is a commonly used System for controlling response effects of a dynamic system.

PID my be achieved by developing and embedding automatic tuning for the settings, or by inputting bespoke parameters based on observing trial runs with continual refinements and incremental changes.

Plug & Play

Clever Winder

In summary, this clever Winder has been developed to be independent of other controls and system, and has the ability to connect to these  when required on the most up to date equipment.

A maximum mechanical speed of 50 metres per minute was set by 2M whilst developing this Control System.

Contacts, Connectors, and Crimps

Male Pins & Female Sockets

Plugs and Sockets, which enable the secure transmission of power, signal, and data, are composed of conductive contacts (male pins and female sockets) housed within insulated connectors (bodies).
These components are designed for specific applications, ranging from domestic appliances to industrial power systems.
  • Pin Contacts (Male): Protruding pins that fit into female receptacles.
  • Socket Contacts (Female): Recessed, spring-loaded contacts that receive the male pins.
  • Crimp Contacts: Used for reliable, solder-less connections.

Contacts, Connectors, and Crimps

Contact Materials (The Conductive Elements) 

Contacts are the core conductive elements, typically made of brass or phosphor bronze, and plated to improve conductivity and resist corrosion.

  • Copper/Brass: Commonly used for base conductivity, often tin-plated for cost-effective, durable connections.
  • Silver/Silver-Nickel: Used in industrial, high-temperature, or high-current, demanding environments for optimal, long-lasting conductivity.
  • Gold Plating: Often used in sensitive electronics or data applications for superior oxidation resistance.

The following slides will show you some examples of both the Male & Female Contacts, as well as Silver & Gold plated Contacts.

 

Contacts, Connectors, and Crimps

CDFD 0.5

This part is an ILME Contact Pin:

It is Female.

It is Gold Plated, for Optimal Conductivity and Anti-Corrosion.

It is 10 Amp, used in Plugs & Sockets passing up to 10 Amps of Current.

It is 20 Awg, which stands for American Wire Gauge. Used since 1857, this System indicates wire thickness accommodated by the Contacts & Connectors, with smaller gauge numbers indicating thicker wire accommodation.

 

 

Contacts, Connectors, and Crimps

CCFD 2.5

This part is another ILME Contact Pin:

It is also Female.

It is Gold Plated, similarly to the previous example.

It is 16 Amp, used in Plugs & Sockets passing up to 16 Amps of Current safely.

It is 14 Awg, which means that it can house wires thicker than the previous example.

Contacts, Connectors, and Crimps

CCFA 0.5 & CCMA 0.5

By this slide, if you’ve an eagle eye and an inquisitive mind, you may have a question along these lines:

Hang on a minute! Those Contacts look different, but they’re both Female?

Are you sure? Did you mean to say that CDFD 0.5 is Male, and CCFD 2.5 is Female?

That would make more sense, as the latter appears to be a Receptacle, whilst the first appears to be a Pin?

Did you have such a question to ask? Are you like I am?

Male & Female in the context of Contacts used in the production of Plugs & Sockets, refers to the final destination of the Contacts – i.e. it hasn’t anything to do with how they appear to the naked eye, rather it refers to whether or not the Contacts are to be fitted into a Plug or a Socket.

By way of example, this image shows a CCFA 0.5, a CCMA 0.5, a Plug, and a Socket.

 

Contacts, Connectors, and Crimps

Contacts, Plug, and Socket

At 2M, Plugs & Sockets are handmade on a continual basis for bespoke Control Panel and Cable Builds. The time it takes to build a Plug & Socket depends on it’s complexity.
Discuss your Enquiries & Specifications so we can get you booked into our Diary & Workshop Production Runs:
To round up this Case Study, the is an overview of this rather more straightforward-looking example for laymen eyes:
A Female Contact, a Male Contact, a Female Socket, and a Male Plug.
In summary, the sex of your Contacts in the Workshop may be misleading to your naked eye, but the sex of the Plug is always Male, and the sex of the Socket is always Female. Experience will strengthen your recognition, recall, and muscle memory in Automation, as with any other Industry.
Have a great day!

Consultation

Equations & Stipulations

2M was created against a back-drop of experience. One particular experience was that of being motion control experts who were accustomed to being subcontracted by larger companies who didn’t have the same specific skill-sets in-house at the time.

Therefore it wasn’t unusual being tasked to apply niche expertise to develop solutions under the umbrella of larger providers.

Although always grateful for such opportunities, it was noted that perhaps things could be done differently.

Consultation

Equations & Stipulations

We set out to improve on this within the industry, as we believe that everyone should be appreciated for their work and contributions, no matter what area they work in.

As such we’ve always embraced transparency and giving credit where credit is due within our collaborations and relationships. We believe this fosters a happy environment which encourages everyone to contribute, develop, and thrive.

Consultation

Following on from that premise, we believe that everyone who’s working authentically and freely is a think-tank of experience.

As such we’re always happy to hear where you’re at and partner up to fill any gaps or indeed to verify specifications as clients develop their ideas, installations,  solutions, and products.

We provide consultations using our most up-to-date knowledge to assist in development specifications. If you’d like to know more about how we can assist in software/electrical/and mechanical fundamentals, sizing, and standards, then please feel free to contact us.

Control Cabinet Build

What it takes to build a robust & tidy Control Cabinet at 2M

Here we are on Day 1.

The enclosure door is marked ready for cut-out in accordance with the electrical panel-drawings layout details which you can also see in this photo.

Control Cabinet Build

Here’s the complete panel cut-out using jigsaw and metal hole-punches.

All bare edges have been dressed and painted with the relevant RAL colour.

Control Cabinet Build

Here are the handy hole-punches used to make the holes for push-buttons and lamps fitted in the cabinet doors.

Look out for our upcoming updates next week  including “arm fitting” and much more.

Control Cabinet Build

Here is our empty control panel. This one is made out of mild steel, sprayed to a standard RAL colour.

Cabinet specifications meet client requirements, taking into consideration environmental site factors.

Control Cabinet Build

Rounding up Day 1, here’s the back-plate which has been removed from the cabinet, ready to be laden and fitted with components.

Control Cabinet Build

On Day 2, we can see the removed back-plate with components laid out according to the electrical layouts, ready for marking and drilling.

Control Cabinet Build

At the end of Day 2.

The back-plate is beginning to take shape with fitted components in accordance to the parts-list and refitted into the control cabinet ready for wiring.

 

Control Cabinet Build

Here we on Day 4.

All the A/C (alternating current) wiring is complete.

At a glance, you may notice a:

  • PLC (Programmable Logic Controller)
  • Circuit breakers
  • Contactors
  • Drives
  • Fuse Switch

Control Cabinet Build

Here we have continuation of wiring with all the DC and control/PLC wiring.

This is the 6 Day milestone on this one-man control-cabinet build job.

Control Cabinet Build

All wiring completed, awaiting trunking lid.

Control Cabinet Build

On Day 8 all trunking-lidding is complete.

It is now time to re-fit the panel doors.

Control Cabinet Build

Panel doors fitted, you’ll note the fan used to moderate temperature inside this control cabinet.

There’s also a drawing-pocket mounted to the inside of a door as standard. This is where the most up-to date electrical drawings for the control cabinet will be stored, alongside completed Hardware Checklists prior to dispatch.

Control Cabinet Build

Ready for testing, here is the final photo on Day 9 to accompany this case study.

Can you notice the isolator-handle that is mounted to the control cabinet door?