Modernization of PR047 SCHULER Press Automation (Donako Sp. z o.o.)

The modernization of the control system and electrical installation of the PR047 SCHULER press at Donako Sp. z o.o. in Wrocław was a response to the need for enhanced diagnostic efficiency and replacement of components with limited availability. The retrofit not only restored optimal machine performance and increased safety levels, but also enabled the implementation of diagnostics worthy of modern industrial systems, transforming operational challenges into predictable and reliable production.

Development need and integration challenge: Restoring full operational capacity

The modernization of the control system and electrical installation in one of the company’s key machines is always a project requiring particular precision. The PR047 SCHULER press is a crucial link in the metal processing chain – specifically blanking – at the facility, however its control system, based on components from previous generations, and the existing electrical installation generated diagnostic challenges. Long troubleshooting times and limited spare parts availability posed a barrier to optimal productivity.

Initial situation: Machine functionality was fully preserved, but the lack of real-time controller monitoring and incomplete, partially outdated technical documentation hindered quick responses from the Maintenance Department. This was a factor that could lead to unforeseen, costly downtime in the future.

Difficulty level: Implementation was burdened with a high level of complexity, as the machine contained many components of unknown status, connected by the original installation. The limited two-week machine shutdown period required maximum efficiency of on-site work. Moreover, it was necessary to untangle the complex signal communication with independent sheet metal feeding robots. Our goal was to guarantee the integration of all structural components with the new control system and improve their operation.

Course of action: The key to success was detailed component inventory and on-site signal verification, in close collaboration with the client’s experienced engineers. To streamline processes, we decided on complete replacement of the electrical cabinet and automation, concluded with FAT and SAT tests, as well as rewiring of nearly all devices. We implemented a Siemens S7-1500 PLC controller with ET200SP island and a modern Siemens HMI panel with TiaPortal software. Precise process monitoring was ensured by two advanced encoders: one for reading the press ram position and another for accurate sheet metal feeding. We also modernized the feeding drive and replaced the mechanical cardan shaft with a dynamic pneumatic actuator.

From mechanics to advanced automation: Guarantee of process continuity

The industrial press automation modernization aimed to transform the machine’s operating method, increasing its predictability and ease of operation.

Diagnostic challenge: The control system relied on mechanical cams, and diagnosing potential disruptions required time-consuming inspection of physical components. The machine did not offer advanced monitoring of key parameters in real time.

New ergonomics and control: The press automation is now managed by a reliable PLC controller, which ensures operational stability and reduces the probability of potential failures. And if one occurs, diagnostics are immediate, thanks to messages on the HMI panel. Status information, such as oil level or sensor messages, is available at hand. The implementation of encoders guarantees high precision in both ram positioning and material feeding.

Path to integration: Replacement of 90% of wiring and removal of inactive components allowed for the construction of a stable and modern installation. The commissioning process included I/O tests, calibration and optimization of each operating mode. Final operator training was organized so that the transition to the new system – with the control panel recreated on the HMI panel – would be intuitive for them and would not require revolutionary changes in habits.

Our ZW Automation team delivered:

• modernization system project with description of conceptual assumptions after multiple site visits,
• electrical schematic and control cabinet prefabrication,
• preparation of signal and parts list,
• development of project schedule and cost estimate,
• dismantling of existing main control cabinet and installation of new one,
• new machine wiring, FAT and SAT tests,
• dismantling of feeding cabinet, delivery and installation of new feeding servo,
• delivery and installation of encoders for main drive and feeding,
• dismantling of press cardan shaft and replacing it with pneumatic actuator,
• programming and equipping the press with HMI panel and control buttons,
• complete integration service,
• commissioning concluded with tests,
• operator training.

All of this guaranteed that the machine would return to operation with elevated standards.

“The modernization of the PR047 press control system, after many years of operation on obsolete contactor systems, was very important to us. The solutions proposed by ZWA were based on modern automation systems and support both our reactive actions – we now have full control over the machine, because we see everything on the HMI panel, as well as preventive – messages about the need for periodic inspections have been implemented. Most importantly, obsolete devices controlling individual systems have been replaced with new ones, available on the market.

Additionally – sheet metal feeding precision thanks to new encoders is really great progress. During the work, constant contact between us and ZWA automation engineers proved particularly important, who spent a lot of time at our facility to properly design and execute everything. The implementation time was really short and I must commend the proposed control panel layout, which allowed press operators a smooth transition to the new system.” – Tomasz Trzcieliński, Maintenance Manager, Donako Sp. z o.o.

Conclusions and the future of automation

Further perspectives: The PR047 SCHULER press automation modernization project is proof that advanced industrial automation allows for significant extension of the life cycle of even the most worn-out machines. Our comprehensive experience in press control system integration is a solid foundation for implementing further projects, which may include, for example, sheet metal straightener integration.

ZW Automation: We automate challenges, supporting the continuity of your production.

Want to gain reliability?

If your key machines in metal processing or other production sectors require control system modernization or diagnostic improvement – contact us. We will ensure long-term predictability and operational safety. We will start by planning an audit.