This is a success story of Lenze Lenze in the United Kingdom. When an innovative tableware manufacturer wanted to increase productivity for their energy-efficient products, they turned to United Kingdom-based system integrator CornfieldEngineering to design and build a new rotary polisher. This polisher glazes the pottery, a glass that adheres to the surface of the ceramic, before it enters the kiln for firing. Cornfield used a single controller with four axes and matching modular drives and gearmotors. The new polishing machine is very easy to operate and can glaze up to 1,000 pieces of pottery per hour.
The concept behind the machine came from an end user, Dudson Ltd. in Stoke-on-Trent, United Kingdom. Dudson is one of the leading manufacturers of ceramic tableware. One of their biggest successes is their Evolution range, which claims to guarantee the lowest carbon footprint in the manufacture of any hospitable crockery tableware, anywhere in the world. This low carbon footprint is achieved by "burning", a high-energy operation, and only needs to be "burned" once, rather than the usual two or more times. One of the resulting requirements was the need for a special lead-free glaze on the ceramics before they were fired, which meant that the entire process was particularly sensitive. The tableware produced by this "green technology" has been widely praised in the market, including many large groups, such as the famous Hyatt Hotels Corporation in United States.
This new rotary polisher can handle a wide range of cutlery, from cups and bowls to pizza plates, with diameters up to 400mm. Of the four modules of the polisher, two of the eight heads can be manually loaded using a dry clay model, and a vacuum system is used to ensure that the eight heads are held in a specific position and rotated by a frequency converter to drive the geared motor. The eight heads are then immersed in a large glaze during rotation, causing the drive to be driven by a geared motor driven by another frequency converter. The operator can control the two modules with four heads each via a central monitoring touchscreen panel via the PLC. After a few seconds of pre-compilation in a glaze bath, the ceramic models are returned to their original position, where they are to be sent to the kiln for firing.
Chris Timbey, General Manager of Cornfield Engineering, ultimately selected the Lenze p300 panel controller for their equipment. The P300 combines a high-quality touchscreen with a PLC controller and its dual functions to simplify the controller system, be economical, and easy to install. The screen sizes are available in 4.3, 7 and 10 inches, and both include UPS and SD memory cards. The P300 controls the device's two modules via four axes. The operator can select the speed, position and dwell time predefined in the menu, or manually control it himself. The device is also supported by the Lenze 1000 system
The supplied remote I/O can also be connected to the p300 controller via CANopen.
The choice of rotary geared motor is somewhat unusual. In order to be able to cover a wide range of speeds, from small cups to large saucers, and to take into account the fact that the working environment is often too dirty to be ventilated with high-power blowers, Lenze equipped them with bevel gear units GKR03 and Lenze 8400 StateLine frequency inverters rated at 87 Hz. This solution increases the rated speed of the motor up to 2500 r/min and extends the speed range to 24:1 without the need for forced ventilation. Another advantage of this option is that it can be accessed
High speed to increase motor power, and optional small size to save space.
In order to ensure that the clay model is accurately immersed in the glaze, the geared motor is also required to provide accurate positioning and compile from the clay model. Here, Lenze motors are equipped with 128 pulses/rev encoders and are available in standard and low-power options. Positioning control is carried out by a Lenze 8400 HighLine frequency inverter that supports up to 15 selectable positioning points and corresponding motion profiles. The frequency inverter can also be connected to the central p300 controller via CANopen and has a STO safe torque disconnect function.
Cornfield Engineering designed, built, installed and commissioned the new rotary polisher. Chris Timbey, Managing Director, has a high evaluation of Lenze: "Lenze has a wide range of products that enable us to provide us with cost-effective control and drive products that are suitable for our applications, in addition to ensuring product performance. Lenze products have helped us to have a polishing machine that is very easy to operate and can also handle our ceramics gently and accurately. The polisher even has a vacuum monitoring system to help us prevent any ingestion of the glaze. "The efficient operation of this system ensures a throughput of up to 1,000 units per hour. Cornfield Engineering is one of Lenze's key engineering partners in the United Kingdom.
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