The partnership began in 1983 with the control systems for the AKS 4410 welding machine and the SV 600 plastering machine. To further advance the automation of the machines, the use of electronically controlled drives was the key impetus for a Ferrocontrol control system, along with the corresponding programming and commissioning—all from a single source!
Starting in 1988, URBAN began utilizing the “FPS” (Freely Programmable Control) capability offered by the MAG control system to program the increasingly complex machine sequences in-house. This was—and continues to be—carried out in close collaboration with and with support from Herford, both in program development and commissioning, as well as in the service department.
The goal was always to build and equip a successful machine. This evolved into a solution-oriented and productive collaboration that worked well even in difficult situations.
That has remained the case to this day. This is particularly true when it comes to addressing specific drive requirements, such as AKS-Vario and V-CUT, multi-head plastering machines, …
But even without machine controls, there have been joint developments. These include the so-called “master computer connections” for welding and finishing lines, as well as the latest plans for IoT data networking.
A look back at the seven generations of control systems:
In 1983, the control systems were based on a Z80 system with a hard-coded sequence, a CRT monitor, and a corresponding number of DC servo controllers and motors equipped with an encoder system developed by Ferrocontrol.
In 1988, Ferrocontrol introduced a new generation of controllers called “MAG.” This was based on an enhanced Z80 processor. The CRT displays remained, while the drive side featured new, high-performance controller systems and newly developed serial incremental and absolute encoders. The DC drive controllers and matching motors remained in use. The following machines were built with this control system until 1996: Plastering machines SV600, SV610, SV800, SV810, and the 4-head welding machine AKS1400
Starting in 1995, the system was converted to the “ABUS” system. This system has a decentralized architecture in which the individual units are networked via a bus system, with a control card installed in an industrial PC running the DOS operating system. At the same time, the DARC drive system was introduced, offering significantly increased performance and functionality. In line with the demand for faster, configurable drive units that can also be controlled independently.
The transition to PCs starting 2000 running the Windows operating system, in conjunction with the “RTwin” soft PLC, the new CAN-based bus system, and the DARC drive system—which began in 2000—could not be implemented without technical issues, at least in the early stages. It was only after the soft PLC was converted to the “RTe system” and certain controller issues were resolved that this soft PLC system became significantly more stable and was deployed in: Plastering machines: SV410, SV430, SV530, SV820, SV830, SV840; Welding machines: AKS 61xx, AKS 66xx, AKS 69xx, AKS 8xxx; Automatic window hardware installation machine: FBA2500; Double miter saw: DGU600
In April 2006, Eckelmann, a company based in Wiesbaden, acquired Ferrocontrol in Herford.
Eckelmann has its own control system, “LBM,” featuring a powerful CNC controller. Unlike Ferrocontrol, however, they did not have their own drive technology. Since the CNC capabilities of the DARC systems are limited, it made perfect sense to leverage the undeniable advantages of the Eckelmann CNC in combination with the Ferrocontrol drive package. In addition, the ExCyy controllers, available in various models, provide full-featured CNC and motion control capabilities, combined with a powerful PLC sequence controller. Another advantage is that these modules operate autonomously and independently of the PC hardware and operating system used!
This technology has been used since 2008 for new machines as well as for the gradual retrofitting of existing equipment. The CNC functions and capabilities—such as Motion—and their specific combination options, depending on requirements, are particularly effective in plastering machines.
Starting in 2012, Ferrocontrol introduced the “E-Darc” drive system. The “E-Darc-C,” which has a similar design to the DARC systems, operates in a controller network with a three-phase power supply.
Starting in 2014, the “E-Darc System” was expanded to include the “K Series.” These are available as single-phase controllers in two power classes.
A significant portion of URBAN machines are still equipped with a (Ferrocontrol) Eckelmann control system. The high technical requirements and their implementation in terms of CNC-based drive technology are particularly evident in the VARIO and V-CUT welding machines, as well as in the multi-head trimming machines. There, the “CNC” enables dynamic, independent, yet simultaneous, parallel machining on different levels, which can be linked with additional motion functions as needed.
Starting in 2019, the latest “UBM” control system will be used as the CNC and PLC controller for new machines. The E-Darc-Ci system will also be introduced as the successor series for the drives. The plan is to gradually upgrade the existing machine equipment to this system.
Let’s keep going!
