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Avoca

Project Name:

Machine rebuild for CE Compliance.

Project:

Gauntlet machine.

Client

Avoca

Main Contractor::

CXControls

Location:

Manchester – Client tested

CXC HQ – Refurbishment

Slovenia – Final Destination

Value:

Confidential

Sectors:

Machinery / Functional Safety

Services:

Design, Engineering and System Integration. 

Overview

CXControls were engaged by Avoca initially to perform a Machine Safety Gap Analysis on their existing gauntlet machine to establish operational readiness in order to meet CE Compliance.

The machine weighed 8 tons, with two sperate sections, consisting of a:

  • Reel-feed end section.
  • Pre-heat and main oven sections.
  • Pneumatic clamping and cylinder sections.
  • Several linear servo motors and drives.
  • Hotwire cutting station.
  • Conveying and end collection.

The Challenge

To meet harmonised standards for machinery in the European market and ensure CE Compliance.

The Solution

CXControls approached project in phrases.

Phase 1 – To perform a Gap Analysis on the imported machine including Machine Safety HAZOP and resulting LOPA (Layers of protection analysis), to establish a baseline design criteria for improvements. 

Phase 2 – 

  • A complete strip out of all non-compliant electrical circuits and wiring
  • The replacement of main drive panel, PLC control panel, and electro pneumatic controls panel.
  • The introduction of a functional safety architecture to meet the minimum SIL 2 (Safety Integrity level).
  • Rewrite of existing software code using Mitsubishi GS Works 3 for the existing PLC and servo axis controllers.
  • Supplying installation of new SIL 2 rated switches, all machine access and guarding.
  • Complete rewiring of the machine including all new and existing control devices.
  • Final commissioning client witnessing, compliance pack and handover.

The Results

The refurbished machine successfully met European harmonised standards for CE Compliance. It was tested at CXC works and again at the client’s site before being shipped to Slovenia for full time service and operation. 

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