Saia-Burgess

Modern bar loaders for high-speed lathes

Fully automated bar loaders deliver bar feedstock to lathes and machining centres. They have been automated with STEP® 7 programmable controllers of the type PCD xx7 from Saia-Burgess Controls. Today, our customer is the market leader in the field of bar loaders for lathes. As well as Europe, the company is also present on the US market and in Asia, with its own factories and around 30 exclusive agencies.
Saia® developed a portable machine HMI with various expansion levels, based on its S-HMI products.

Control of a fabrication line for fully automated comb binding

This fabrication line for fully automated comb binding is a world first and has great rationalization potential. Comb binders are punched out of low-cost foil rolls, formed and they conveyed to the book-block, which has previously been punched with the necessary binder perforations. All the installation’s electric drives use 53 (!) modern stepper motors.
Programming for the Saia® PCD controllers was produced with the PG5 software package in a GRAFTEC flowchart, making use of the function block library for H2 stepper motor modules.

Lötschberg basic tunnel - control and monitoring with Saia® PCD

As part of the European high-speed rail network, two basic alpine crossings are currently under construction at Loetschberg and Gotthard. The Loetschberg basic tunnel is about 35 km long and goes from Frutigen in the Kander valley to Raron in the Rhone valley. When it opens in 2007 it will, together with the Simplon tunnel, form the first, fast North-South rail link across the Alps.
Safety is the prime consideration: The companies MST System Engineering Ltd, Belp and TSA Telecom Ltd, Lausanne use Saia® PCD controllers for major project parts, such as: air conditioning, ventilation, fire prevention, escape route signalling and radio equipment.
Many systems are duplicated. Redundant communication takes place across Saia® PCD2.M480 controllers.
In total, there are over 30,000 data points, 1470 RIOs on 660 PCD controllers and 420 HMI stations.

Dynamic warehouse systems with Saia® PCD in production machines

The customer is a group of companies with by far the world’s largest production volumes in the field of dynamic warehouse systems. As the absolute number 1, this group has factories in America, Europe and Asia. In Germany and the USA there are in total four development centres. To satisfy differing customer and market needs, a multi-brand strategy is practised.
Over a period of almost two years, a working group of control specialists drew up a comprehensive market survey and technology evaluation. The aim was to define and implement group-wide the same modern control platform for all production machines.

Saia® PCD for Web based control and maintenance of 750 kW generators

A close cooperation with Saia-Burgess, whose PLCs have been widely used for many years by the customer, has given rise to one of the first web server applications for the control and management of a co-generation group of 750 kW.
All the web pages, which relate to the management, command, fault detection and formulation of operational data can be called up from any PC which has a standard web browser such as Internet Explorer, Netscape Navigator or other. In consequence there is no need for the presence of an operator to allow operation and interaction with the installation on site.

Safety system for travelling cranes with Saia® PCD2.M170

In response to the decree of 2.12.1998, the company Paradia has perfected an anti-collision system to ensure the safety of automotive mobile equipment on rails. The development of this system, based on the calculation and communication performances of the Saia® PCD2.M170, aims to reduce and even eliminate the risk of serious accidents suffered by people working in the environment of this type of mobile equipment.
The anti-collision system is designed to authorise, limit or prohibit the movement of the crane, the direction of the carriage and the elevation height, depending on the situation and present obstacles.
It’s possible for the systems to communicate to each other, by connecting them to the company’s intranet connection, thanks to the Ethernet-TCP/IP options of the PCD2.M170 controller and the OPC server for the computer part. It’s possible to configure and supervise all the cranes from remote. And finally, to perfectly integrate the system into the automatic production management.

Dynamism and precision with Saia® PCD controlled vertical presses

This, in brief, is the approach which makes OMF Turra an outstanding company. It is a specialist in the production of vertical presses intended for the injection printing of thermoplastic techno polymers using inserts.
O.M.F. Turra has been controlling its own machines using Saia® PCD since 1984. These units were selected for their reliability and for the advanced solutions which they offer: characteristics which, combined with considerable experience in programming, have led to excellent results.

Saia® PCD controls the KUPA short rod feeder

KUPA’s «SERVO FEED» is the leader in short rod feeders. This is the first time that a 3-axis servo drive has been used for this purpose. This new KUPA product guarantees uncompromisingly accurate control, and a new, low-noise rod separation.
The control and regulation technology in this new generation of feeders was developed using the PCD2.M127 from Saia® and with Stöber’s FAS 4008 (frequency converter).
In order to reduce downtime the new «SERVO FEED» is offered with optional visualisation of the error and diagnostic data information via an Intranet or Internet (web server), and with error messages transmitted via SMS.
The main factors influencing the decision to choose the Saia® PCD2.M127 were KUPA‘s available STEP® 7 know-how, the link to Sinumerik via MPI and the professional support provided through Saia-Burgess Controls during the pilot phase.

Saia® PCD for the preventive monitoring of Schuler Presses

Seeking a substantial increase press operating times and to prevent machine breakdowns, the Schuler company developed a procedure for the rapid capture and evaluation of temperature rises in big-end bearings and tappet guide-rails.
The first version made use of a Saia® PCD4 with W500 analogue modules, a data logger from Uhlemann Software Engineering and an EXOR terminal with integrated IPC.
A system based on the Saia® PCD2.M480 was developed. The new system additionally monitor the pressure forces and mechanical overload occur (e.g. tool knock-outs, big-end bearings from tappets) will switch off the press within a few ms.

IDEA: Machines for diamond tools with Saia® PCD

The company «IDEA» aim to construct high-quality machines, technologically up-to-date, with outstanding performance levels and with a user-friendly and logical man/machine interface which uses touch screen operating terminals.
After a careful analysis of the market for PLCs, IDEA decided to select the Saia® PCD2 series for its undoubted qualities, the efficient technical support, and last but not least, for the price: a combination which is not found elsewhere. The company logo, Machines & Maintenance, accurately reflects its aims: the construction of top-quality machines and a rapid response, anywhere in the world, immediately problems or difficulties arise, thanks to standard modem connections for tele-support.

Manufacture of semi-conductors with Saia® PCD

The company has over 15 years experience in the construction of RTP and RTCVD machines (Rapid Thermal Processing or Rapid Thermal Chemical Vapour Deposition) for the manufacture of semi-conductors.
Since its origins, Saia-Burgess has been the privileged supplier of JIPELEC. From the PCA to the PCD2.M170, Saia-Burgess has always anticipated and responded to the required technical developments. (Memories, cycle times and communication capacity) For example, the JetStar, which is equipped with 3 PCD2s linked by S-Bus and to a PC.
1 × PCD2.M150 with analogue I/O modules controls and commands the temperature sensors via a serial link.

Saia® PCD for the production of electric motors

Since 1989 CO.MA.S. has been a leading company in the design and production of a wide range of machines suitable for the construction of electric motors.
CO.MA.S. has always installed Saia® PCD on its own machines, a solution chosen to obtain the maximum level of reliability and performance over time. Particularly valued are the significant communications abilities of the PCD2 series. Their easy usage and the large number of serial ports present on the CPU allow a secure and dependable interface to be made with the instruments on board the machine.

Own experience

The Saia-Burgess Group produces 165 million switches and 30 million drives each year. Saia-Burgess has 13 production sites, which together have more than 3000 employees.

In this business it is no longer possible to be successful unless you have a high degree of automation. The rapidly operating production machines need effective controls, particularly for the assembly and testing processes, and this calls for an automated production infrastructure.

This makes Saia-Burgess itself a large customer for Saia® PCD products. This constellation has been very useful and important to us since the very beginning of Saia® control technology. We can try out the automation solutions for ourselves, although we do not present ourselves to the market as a solutions provider.

6 months before sales release the production of micro-switches in Hatvan (HU) was already being controlled by 8 Saia® PCD3.Mxxxx without any disruption. At this site we want to thank those of our colleagues in the Saia-Burgess Group who help us to test and continue to improve Saia® PCD products and technologies in practice for our customers.

Process technology for biogas systems with Saia® PCD2 and visualization

Last year, this company, which is based in Bad Saulgau, built approx. 35 biogas systems with standard Saia® PCD 2 technology from Saia-Burgess Controls. The entire process is controlled with Saia® PCD and monitored with a visualization system.
In the simplest case, liquid manure flows from the barn directly into the receiving cesspit and from there to the fermenter. Solid substrates can be delivered directly into the fermenter with the help of feed screws, feed pistons, water-jet shafts, etc. Almost any organic substance can be fermented as a substrate in agricultural biogas systems, except for woody materials (lignin).