Modernizing existing machines is a crucial factor for efficiency, flexibility, and future-proofing in production. As part of this project, an AMAS milling and trimming machine for wine barrels was comprehensively modernized and brought up to the latest state of technology.
Conversion to Modern Control Technology
The original control system based on a Schneider controller was completely replaced by a powerful Siemens S7-1500. This now forms the central element of the machine control and enables significantly higher performance, stability, and expandability.
The drives are now controlled via PROFINET. This has greatly expanded the parameterization options. Milling parameters can now be set precisely and flexibly, allowing the machine to be optimally adapted to different barrel geometries.
Maximum flexibility through software solutions
A significant advancement lies in the complete integration of mechanical adjustment processes into the software:
- The lifting height adjustment is now fully automated via the control system
- Changing to different collet types is possible without mechanical intervention
- Setup times are significantly reduced and operator errors minimized
Additionally, an optical distance measurement has been integrated. This allows for highly precise positioning of the milling tools without the sensors needing manual adjustment. The result is consistently high machining quality with simultaneously reduced maintenance effort.
Powerful HMI and intelligent data management
The new HMI offers extensive possibilities for managing and optimizing production:
- Management and parameterization of several hundred collet types
- Integrated tool database for fast tool changes
- No need to reset tools
- Reusable data sets for maximum efficiency
These features enable standardized and reproducible production – independent of the operating personnel.
Transparency and Production Analysis
Another focus of the retrofit is on data acquisition and evaluation:
- Automatic recording of cycle times and production output
- Graphical display directly on the HMI
- Identification of optimization potentials in real time
The collected data can also be forwarded to higher-level systems.
Integration into ERP and Control Systems
The machine is now fully prepared for the digital factory:
- Provision of production data to ERP systems
- Feedback on order status and performance indicators
- Support for continuous production tracking
This enables seamless integration into existing IT infrastructures.
Conclusion
The retrofit not only technically modernized the AMAS milling and trimming machine but also significantly expanded its functionality. The combination of modern control technology, intelligent software, and comprehensive data collection ensures:
- Higher productivity
- Significantly reduced setup times
- Maximum flexibility
- Future-proofing of the system
The project impressively demonstrates how existing machines can be brought up to the level of current industrial requirements through targeted modernization.