A reliable and easy to use system focused on increasing productivity and reducing scrap.

Major benefits: Back to back jobs to reduce scrap Material tracking and dual encoder support for reducing scrap Network monitoring and manufacturing transfer facility Precision counting Production data sorting Production audit log Product database Velocity profiling for maximising production Output stack tracking and weight display Supports any number of in-line punching stations Label or ink jet spray printer Easy to learn and use Reliable Customer focused support   LESS SCRAP LESS IDLE TIME MORE CONTROL

Panel Touch Screen Controller

 
Quick Links to this page

Job Queue Motion Control Product Designers Networking Internet Browser Enabled Operation Overview Productivity Reliability Scrap Reduction Supported Configurations Tuning with Motion Analysis

Fixed Position In-line Punching No manual location adjustment necessary as steel is correctly positioned under each tool

Other Links

Job Import File Specification - Free documentation for transferring manufacturing data to controllers.

 
HIGH VOLUME MANUFACTURING
The Insmart control system has been purposely constructed for reliable high volume manufacturing.

	Steel wall frames and roof trusses produced by Insmart control software

 
CONFIGURATIONS
Adaptable to many different manufacturing configurations.

Click to view larger image.

			Stud and Truss
			Loop and Flying Shear
			Cut To Length Slitters
			Door and Window Frames
			Recoilers and Perforating

Any number of in-line stations can be configured to work as "stop to operate" or operate "on the fly". A station can be a pneumatic or hydraulic tool or a spray printer. Guillotine modes - stop to cut, fly cut, or slow to fly cut. Fly refers to the material moving whilst the operation takes place. The controller supports entry and/or exit encoders, splitting and recoiling, multiple machine beds connected by a demand loop, perforating press and feeder, drop stackers, suds pump, guards and emergency stop.

 
UPGRADE FOR DOS CONTROLLERS
Insmart can supply ISA motherboard computers and software to upgrade Colrol DOS controllers to this Windows control system.

 
UPGRADING OTHER CONTROLLERS
With a little electrical work virtually any line can be upgraded to take advantage of all features. We commission each installation to make sure the system is connected and configured correctly and provide on-site training. Typically an upgrade requires around 3-4 days of down time.

 

ELECTRICAL CONTRACTORS If you have clients in the steel industry and would like to be involved with supplying professional control systems please contact Insmart for further information.   MOTION CONTROLLER SUPPLIERS The Insmart control software is able to use any motion control interface that can communicate with a Windows XP PC. Please E-mail a proposal to Insmart for consideration.

 
INDUSTRY LEADER IN AUTOMATION AND CONTROL
Insmart continues to pioneer advances in roll former control. Our ongoing research and development means the level of excellence provided by our controllers simply keeps growing.

Spending time on-site is an important part of our ongoing research and development. As well as meeting client expectations we are interested in making the system work efficiently for the people who have to operate the machines.

 
TIME SAVING PRODUCTIVITY BENEFITS

Accepting jobs over a network increases production as the roll former is not idle whilst the operator "keys" in jobs. The data handling screens allow the operator to quickly and efficiently organise and submit jobs for manufacturing. Velocity profiles can be created and easily selected to match the speed of the roll former to requirements such as going slower when rolling thin material to prevent buckling. The roll former can be programmed to automatically reduce speed when short items are being produced. This allows the operator to keep up without having to stop/start the roll former. A job tracking system reduces errors by making sure jobs are manufactured on the correct controller. A production history facility allows operators to view recent production and re-select any damaged items so that they can be manufactured again. Whenever an operator must manually enter a job a product database may be used to recall standard job items. This reduces mistakes and data entry time.

 
SCRAP REDUCTION

The Insmart controller has features and material tracking counters to ensure a roll former uses the least amount of scrap possible when loading a new coil, using only part of a coil, or completely finishing a coil. A pendant execute mode allows in-line punches to operate whilst material is being "inched" through the roll former. Coil Change Over Scrap - Analysis of material tracking and scrap reduction.

PRODUCT OVERVIEW

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The control system operates on a Windows compatible computer connected to a motion controller and digital I/O. A number of Ethernet connected devices are supported and can be used at the same time. Being PC based there are no memory or storage limitations. Networking and compatibility with corporate networks is straight forward and support and maintenance of the PC is not vendor specific.

The control software has been specifically developed for the control of roll forming equipment.

Although the software has built in support for touch screens most operators seem to prefer using a standard LCD monitor with a keyboard and trackball.

PROVEN RELIABILITY
There are over 70 Insmart control systems working day in and day out all around the world. Most service requests are for trouble shooting electrical equipment failures.

FRIENDLY INTERFACE
Menus are simple to follow with explanations and examples provided in the on-line help system. Large text and buttons enhance visibility and viewing distance.

HELPFUL PRODUCT DESIGNERS
Custom made product designers can be incorporated into the control system to assist with accurate data entry.

Product units are converted into manufacturing units so that "finished" dimensions can be used for data entry. This reduces errors, saves time and makes the process very easy.

Standard items can be designed and saved to a database where they can be recalled and submitted for manufacture.

A Garage Door Designer

A Door Frame Designer

A Window Frame Designer

EFFICIENT NETWORKING
With in-built Windows networking the control system not only becomes part of the corporate network but can also be supported, upgraded and have problems diagnosed remotely across the network or Internet.

Manufacturing jobs such as trusses or house frames can be easily transferred across the network directly to the control system.

A job import display handles the queuing of jobs until they are manufactured. Operators have the freedom to choose the order in which jobs are manufactured. Items in the job queue can be rearranged until an item "enters" the machine for manufacture.

INTERNET BROWSER ACCESS TO PRODUCTION DATA
The Insmart control software is able to serve production data to any Internet browser across a network.

With this facility managers are able to remotely view perfomance and production related information.

PRODUCTION DATA SORTING
The items for a customer order are sometimes made from different coils. The Insmart controller automatically sorts data into coil lots so that when a coil is loaded all items across all jobs are manufactured at the same time.

JOB QUEUE
A job queue is made up by selecting products and quantities from a database or by using the network feature to automatically import production items. Each item records the following information:

Type of material required such as gauge and/or colour, Quantity, Job code/number, Client description, Marking text to identify the item,

Jobs can be queued according to any requirement such as coil width, colour, gauge and roll former configuration etc.

Items are queued for manufacture in the job queue

OPERATION
A green run button is depressed to enable automatic production. The control system enables the machine, and a knowledge base about the machine and the products is used to produce the required products.

All manufactured items are recorded in a production audit list that contains the date and time of manufacture, operator's code, and the linear count when the piece was guillotined from the coil.

When an item is manufactured with a defect it can easily be submitted back to the top of the job queue for manufacture again by simply highlighting the item from the production list and selecting a Scrap option.

MOTION CONTROL
The controller supports the use of variable speed drives with motion control systems and also PLC counter controlled slow down to stop systems.

Motion controllers use PIDVFA control loops to provide fast movement and accurate stopping. PIDVFA is an algorithm that uses Proportional, Integral, Derivative, Velocity Feedback, Velocity Feed forward and Acceleration Feed forward.

Motion Control Video Click on this link to view a video. The link contains an activex control used to play the video that might get blocked. Select the "launch in external player" link if you do not wish to use the player.

MOTION ANALYSIS
Sometimes motion control equipment require tuning.

The control system is able to record and graph the velocity of the material as it is transported through the machine. This ability provides the information to allow the motion control parameters to be tuned for optimum performance.

The graph below is an actual recording of material being notched at different locations. Short distances between operations result in slower movements limited only by the acceleration parameters for the drive.

CONTROL SYSTEM FLOW CHART OVERVIEW
The following chart shows how manufacturing data is processed by the control system.

DOCUMENTATION
The software is supplied with on-line help written in English. A printed manual is available by request.

SERVICE AND SUPPORT
Except for the electronic interface the computer equipment is standard Windows PC compatible equipment so service and spare parts can be independently obtained.

REMOTE ADMINISTRATION
Remote administration is very rarely required. Insmart uses a remote access product called VNC to perform remote administration tasks with the control software.

EXPERT HELP
Experienced professional engineers at Insmart are available to promptly deal with any system or software query.

EQUIPMENT REQUIREMENTS
Cabinet, Windows XP computer with touch screen or LCD screen, Insmart control software, motion control and digital I/O interface.

AFFORDABILITY
Software license fees start from a very competitive small fraction of the total development cost and there are no royality fees or ongoing costs.

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