CASE STUDY · BESPOKE ENGINEERING

Rotational Moulding Machine Automation

Upgrading a manually operated machine with integrated hydraulics, PLC-based automation and touchscreen control of burn and rotation times.

Machine AutomationPLC & HMIHydraulic EngineeringElectrical & Controls

Existing rotational moulding machine upgraded with hydraulic and electrical controls

PROJECT OVERVIEW

From manual operation to integrated machine control.

Active Hydraulics upgraded an existing, manually operated rotational moulding machine with hydraulic and electrical control systems tailored to the application.

The work combined a new hydraulic power pack and control valves, replacement hoses and pipework, and a new electrical control panel with PLC programming and a Human-Machine Interface (HMI).

The upgrade brought the machine’s hydraulic functions and electrical controls together, giving operators a touchscreen interface for configuring burn and rotation times for different products.

THE CHALLENGE

Integrating automation into an existing machine.

The hydraulic and electrical upgrades needed to work within the existing machine arrangement. The key requirement was to connect the hydraulic supply, control valves and operator inputs through a coordinated control system suited to rotational moulding.

The operator interface also needed to accommodate different product requirements, with accessible adjustment of the burn and rotation timings.

THE SOLUTION

Hydraulic integration and PLC-based automation.

Active Hydraulics installed the new power pack to supply the machine’s hydraulic functions and integrated control valves to manage their operation. Replacement hoses and pipework connected the hydraulic components within the existing installation.

A new electrical control panel housed the automation hardware. PLC programming coordinated the machine’s automated functions, linking operator inputs from the HMI with the electrical controls and hydraulic system.

New hydraulic power pack and integrated control valves.
Replacement hydraulic hoses and pipework.
New electrical control panel and HMI operator interface.
PLC programming to coordinate the automated functions.

**Hydraulic power and electrical controls**The new hydraulic power pack and control-panel assembly, shown together in the workshop.

**Touchscreen operator interface**The installed panel combines an HMI touchscreen with physical switches, indicators and an emergency-stop button.

OPERATOR CONTROL

Adjustable timings for different products.

The HMI touchscreen provides a menu-driven interface through which operators can select and adjust burn and rotational times. These settings allow operating times to be configured for different products when changing between moulding applications.

The HMI provides the point of interaction; the PLC translates those inputs into programmed machine functions. Together, they connect operator settings with the coordinated operation of the electrical and hydraulic systems.

Burn timeAdjustable through the touchscreen menu to suit the product’s operating requirements.

Rotation timeConfigurable rotational timing through the same operator interface.

Heating stage of the rotational moulding process — The heating stage of the moulding process. Burn and rotation timings are configured through the upgraded HMI controls.

THE RESULT

An existing machine with more adaptable control.

The completed upgrade brought the hydraulic power pack, valves and replacement connections together with PLC-based automation and touchscreen operation.

Operators can configure burn and rotation times for different products through one menu-driven interface, providing a more accessible and adaptable way to manage changing moulding requirements.

IntegratedHydraulic functions and electrical controls coordinated within the existing machine.

AccessibleTouchscreen menus provide the operator interface for timing adjustments.

AdaptableBurn and rotation times can be configured for different product requirements.

UPGRADING AN EXISTING MACHINE?

Let’s discuss your automation requirements.

Talk to Active Hydraulics about hydraulic upgrades, control panels and machine automation for your application.

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