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Synopsis of Big 3’s Front of Line (FOL) Control System Solution

  • Situation: A Big 3 auto manufacturer purchased a Front of Line (FOL) system that was designed to destack both steel and aluminum blanks on an AA3X press line.
  • Customer Objective: Upgrade to maintain market competitive position.
  • Requirement: Front of Line (FOL) Control System Solution to meet the customer's Global Controls Standards.
  • Brock Solutions' Role: Designing the complete electrical system architecture. Procuring all panel-related components and fabricating the panels. Writing the Functional Specification outlining the complete FOL controls solution. Programming PLCs and designing and programming HMIs. Programming and integrating drives. Interfacing data and controls with both the existing Master Operator Console and the existing press. Conducting I/O emulation testing to assure the system functioned according to specification prior to installation. Conducting Factory Acceptance Tests (FATs) with the customer. Commissioning the system.
Big 3's FOL Control System
  • Main Technology Components: A-B Guardlogix Safety PLC system, Siemens MP370 HMI, Devicenet distributed safety I/O, Siemens ET200 IP20 I/O, Turck IP67 I/O, PowerFlex drives, ControlNet, Ethernet.
Contact us for the complete project profile, which showcases the solution in greater detail and highlights customer benefits.

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