RichardH

FX program for rewinding machine

11 posts in this topic

Hello, I recently discovered a paper rewinding/slitting machine using FX PLC's has dropped it's program. It seems the rom cassette is missing and the battery has failed. I'm looking for a program from anyone with a similar process machine that we can use to adapt to our machine. Hopefully it could significantly reduce the cost of re-writing from scratch!
Any help is greatly appreciated.

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Hi Richard, sorry can't help with a program from a similar machine but I have experience with winding and slitting machine and Plenty with Mitsubishi PLC. Contact me if I can be of assistance.

 

Ray

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Hi Ray, thanks. I have had a couple of people look at it in the past week and both advise it is a lengthy process to work out the flow chart from the schematics, then write the program from scratch. It is a long shot to hope someone has an actual copy of a program to work with but I'll keep trying!

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Richard, 

If you hope that any rewinding/slitting machines, even like yours controlled by Mitsubishi FX PLC, works under the same program and somebody at this forum has such program on their hard disks, you are thinking in wrong direction and you will lose time.

If your machine has an operator panel (HMI) onboard, there are only two way, that might allow to be cost saving:
1) To find somewhere a machine, the model of which is completely identical with yours and which is working properly. Then you could ask somebody at this forum to help you to upload the program from the working machine and to download it into yours. Ideally, it can be done remotely, without travelling to objects.
2) To write a request to the manufacturer, may be they will agree to help  and to send you a program, written on cassette.

To write a new program is possible, however will be expensive and time long exactly.

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Hi Richard, 

good luck and I wish you success, I assume you have no real pressure to get this working. If I can be of assistance contact me.

 

Ray

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Thanks Inntele. Just to confirm, I should be looking at the identical machine's program, rather than a similar machine on identical PLC? I don't have experience with PLC code so I assume from what you are saying, the program for an identical machine could be copied/translated to the Mitsubishi PLC? I have written to the manufacturer, who is investigating. The problem is the control panel was upgraded by another company, that has since wound up...

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Richard?

from experience most of these type machines have different setup parameters, my suspicion is that there have been changes given that the ROM has been removed. Can you confirm FX model? The ROM would have been the Manufacturers base program. Is it dancerbar/tension control?

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2 hours ago, RichardH said:

Thanks Inntele. Just to confirm, I should be looking at the identical machine's program, rather than a similar machine on identical PLC? I don't have experience with PLC code so I assume from what you are saying, the program for an identical machine could be copied/translated to the Mitsubishi PLC? I have written to the manufacturer, who is investigating. The problem is the control panel was upgraded by another company, that has since wound up...

Richard, the working machine, you need to find, should be completely identical (not only its PLC). That fact, your machine has been already modifed by a company, whose service is unavailable for now, is not so critical, if they did not change electrical schematic and did not replace the original automation equipment with another. If they have changed/replaced it, you may face with additional problem. Anyway, would be better for you to work hand by hand with an automation specialist.

Only for illustration. Just recently, I helped to reanimate a paper-cutting machine, the PLC program in which got "holes". Together with client we looked at a number of machines made by the same manufacturer and having the same model name, however, except of one, all were incompatible: either is equipped with another PLC, or with another HMI model, or it has a set of control switches and buttons that is other than the client's model has. Some has been modified by manufacturer, some by service companies. But finally we got a success: one machine had the same PLC, the same HMI and the same set of switches and buttons. While the program we have uploaded from the working machine was not full-compatible with the original, but it helped me to repair the original program and now the machine works fine, according to the original algorithm. It took our efforts, but in result, the cost of repairing by finding an identical machine and uploading its program was in three times cheaper for client's pocket in comparison to the offer from  manufacturer of the machine.

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Hi RichardH,

 

Just a warning: Take also in account that if you write a new program your self also the responsebility has become yours!

If someone gets hurt, loose a finger or even dies due a problem in your software you might face a lot of juridical issues. Just be carefull with these type of actions.

In this case I would advise to look for the manufacturer to solve this problem. A paper cutter can turn out to be a dangerous piece of equipment.

 

Best regards,

Theo V.

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Hi TheoV,

1) RichardH has a problem with paper rewinding/slitting machine. He didn't want to write a new program. Especially, to develop it by himself. 

2) I repaired a paper cutter machine by downloading the copy of manufacturer program into its PLC. That program worked on the machine before the PLC got faulty. I always remember about these dangerous factors and about responsibility. However, who will be responsible for malfunction, if the program in PLC is completely identical with original program, written by manufacturer?

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Hi TheoV & Inntele

Thank you for both of your comments. I am now contacting the original manufacturer to see if they have programs for identical machines on file, rather than similar machines using the same PLC.

Regarding risks, you make an excellent point, however, I am only doing some leg work here. If I find a suitable program, it will be installed by a competent technician. We have two local companies in mind who can both write from scratch, but at enormous cost!

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