Our client needed a reliable control solution for a small labeling machine that previously had no automation. The machine includes stepper motors, limit switches, a label printer, and optical sensors.
Currently, the operator had to control the machine manually, which led to mislabeling, production losses, and frequent maintenance.
Customer Priorities:
Precise stepper motor control for error-free labeling
Integration of limit switches and sensors for safe automatic start/stop
User-friendly HMI interface to minimize operator intervention
Modular and scalable board design for easy maintenance and future expansion
Our Solution 💡
We approached the problem holistically and developed an integrated hardware and software solution.
Hardware
Development of a control board for stepper motors and labeling mechanics
Integration of inputs and outputs for limit switches and optical sensors
Test indicators and status LEDs for easy monitoring by operators
Modular terminals and connectors for fast assembly and simple maintenance
Software
Microsecond-accurate stepper motor control
Smooth start/stop algorithms to minimize mechanical wear
Real-time monitoring of sensors and limit switches for safe operation
Alarm and warning system to reduce the need for operator intervention
Integration & User Experience
Full machine control via HMI
Easy adjustment of speed, position, and labeling parameters
Test functions for simple maintenance and troubleshooting
Technical Details ⚙️
Hardware & Board
MCU: High-performance microcontroller for real-time control
Stepper motor control with microstepping for precise movement
Direct sensor monitoring on the board
Industrial-grade enclosure, dust- and vibration-resistant
Modular design with terminals and connectors for quick maintenance
Motor and Actuator Control
Microsecond-accurate start and stop of stepper motors
Synchronization of motor movements with labeling mechanics
Automatic correction of speed and position deviations
PWM and PID algorithms for consistent speed and positioning
Sensor Integration
Product and position sensors connected directly to the board
Software filters prevent false alarms or unintended triggers
Real-time synchronization between motor movements and sensor data
Communication & HMI
Intuitive HMI interface for easy machine control
Display and adjustment of speed, position, and labeling parameters
Test functions simplify maintenance and troubleshooting
Advanced alarm system ensures safe, uninterrupted production
Embedded Software
Real-time C-based control for maximum precision
Synchronized control of stepper motors, labeling mechanics, and sensors
Modbus and proprietary protocols for integration with other systems
Automatic stop, warning, and safe restart in case of errors
Flexible & Scalable: Solution adapts to various machine models and production lines; additional sensors, motors, or HMI functions can be easily added
Advanced Error Management: Automatic stop and safe restarts increase operational safety and minimize downtime
Operator Adaptation: Intuitive operation shortens training time and reduces human error
The implemented control solution greatly improved the labeling machine’s precision and reliability. Microsecond-accurate stepper motor control ensures perfect synchronization between motor movements and labeling mechanics, virtually eliminating labeling errors. Even at high production speeds, accuracy remains consistent, significantly reducing scrap and rework.
The user-friendly HMI interface minimizes operator interventions. All relevant parameters, including speed, position, and labeling options, can be monitored and adjusted directly via the display. This increases safety during operation and simplifies training for new staff while reducing human errors.
Maintenance and troubleshooting are also significantly easier. The board’s modular design, integrated test indicators, and real-time sensor monitoring allow quick detection and resolution of issues. The advanced alarm system enables automatic stops and safe restarts, minimizing downtime and maximizing production safety. Overall, the solution greatly enhances efficiency, reliability, and flexibility in production.
Data Privacy 🔒
This project is presented without customer or product names for confidentiality reasons. All illustrations are for demonstration purposes only.
