The decoiling line was systematically expanded to enable even bigger sheets to be processed more efficiently. A second straightener was added followed by a trimmer (edge cutter). As a result of all these additions, the installation became a collection of AC and DC motors, various controllers that did not communicate with each other and operations in different places within the plant. If a component failed, it was hard to find the problem. But the customers require continuity and Decomecc also operates 7 days a week. So things had to be improved.  The safety requirements from the machinery directive and the low voltage directive had to be met and performance had to be improved: the number of errors had to be ruled out completely when printing the sheets.

Retrofit  Siemens service experts upgraded the controllers and a number of old DC motors and also introduced numerous functional and safety upgrades. 
Better ergonomics
Siemens service experts replaced the various controllers with a single central SIMATIC S7-1500TF controller which combines all PLC and safety tasks. As a result, complex kinematic functions such as synchronization of the various drives, and integrated safety are controlled centrally. 
All the cables and motor drives (SINAMICS S120 for the line drives and adjustment motors and SINAMICS G120 for the auxiliary drives) are also new. 3 of the 39 motors on the line were still DC motors; these were replaced with AC models (SIMOTICS M and S).  
By combining the existing motors with new drives, it was possible to achieve significant cost savings for Decomecc. 
The controllers are now grouped together in a new electrical room, with space for expansion in the future. As a result of the systematic additions, the old cabinets were dotted around the building. The new electrical room is more efficient and more ergonomic as heat and noise are no longer being pumped into the building. The space that was gained has also made it easier to carry out visual inspections along the line.
Safety and functional upgrades
The current safety requirements from the machinery directive and the low voltage directive are now met. After a risk analysis, barriers were provided where necessary. Some zones are no longer accessible while others have been demarcated using light curtains and light screens. 
There were also a lot of functional upgrades. The PLC is integrated in level 2/3, i.e. it is connected to the ERP system so that orders are read in automatically. Operators used to have to type in data manually which meant that there was a risk of them putting in the wrong dimensions or numbers. Now that reading in is carried out automatically, the possibility of errors has been ruled out completely.  Decomecc also prints sheets. The text used to be added via a barcode but if the operator forgot to scan it, the printing was wrong. Now that data comes directly from the server. 
Another functional upgrade was the electric paper winder. There is paper between the coils that needs to roll up when you uncoil the metal. That used to be done pneumatically but now it is done electrically. This is also controlled by Retrofit for Drive Systems and as a result the paper tears much less frequently.
Energy savings
As a result of the retrofit, the installation also uses less electricity. This is deemed pretty important when there are volatile energy prices. An eco mode was installed. If the installation is not in use for a certain length of time, the components are switched off. The machines consumption used to be 40 kW when it was not in operation, now it is 1 to 1.5 kW. It also reduces the wear and tear on the machine.

Decomecc, a decoiling and metal cutting company, is a high-tech innovative service center offering the full range of metal processing possibilities for aluminium, steel, and stainless steel. From decoiling, cutting-to-length, slitting, and sawing to laser blanking and CNC milling, Decomecc has all expertise in-house and production capabilities on site.