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CASE STUDY

MK2 Backfold Servo Upgrade

Modern Allen-Bradley Servo Controls Restore Full Speed Performance on High-Volume Packaging Lines

The Challenge

A confidential custom paperboard packaging manufacturer in Spokane, WA operates high-volume carton packaging lines running at up to 30,000 cartons per hour. The North packaging line's MK2 Backfold machine — a critical piece of carton-forming equipment — was running on aging servo technology that had reached the end of its reliable service life.

The original servo system presented several operational challenges:

• End-of-life servo drives and motors with no current vendor support, creating spare parts scarcity and unacceptable downtime risk on a high-throughput production line
• Outdated motion control architecture unable to meet the precision and speed demands of modern carton-forming operations
• Existing 240V, 3-phase power infrastructure incompatible with replacement servo hardware requiring a clean 480V supply — necessitating an electrical infrastructure upgrade alongside the controls replacement
• No modern operator interface, limiting operators' ability to monitor servo status, adjust parameters, or diagnose faults without specialized knowledge of the legacy system

The Solution

Logic Control Systems engineered and delivered a complete servo control system replacement for the MK2 Backfold machine, sized for reliable operation at the line's full design throughput of 30,000 cartons per hour. The project encompassed new servo hardware, motion control architecture, PLC integration, and operator interface — all mounted on a new panel backboard for clean installation.

Allen-Bradley Servo Motors & Kinetix Drives

Two new Allen-Bradley servo motors were specified and sized to meet the MK2 Backfold's mechanical load requirements at maximum operating speed. Paired with Allen-Bradley Kinetix servo drives, the new motion system provides precise, high-speed control of the backfold mechanism with the responsiveness required at 30,000 cartons per hour. The Kinetix platform offers full Allen-Bradley ecosystem integration, onboard diagnostics, and long-term parts availability.

SERCOS Motion Control Network

Motion coordination is handled through Allen-Bradley SERCOS motion control, a high-speed deterministic network purpose-built for multi-axis servo applications. SERCOS provides real-time synchronization between the PLC and the servo drives, ensuring precise timing of the backfold sequence relative to the rest of the packaging line's motion.

ControlLogix PLC & I/O

An Allen-Bradley ControlLogix PLC with expansion I/O serves as the machine controller, executing the backfold motion program and managing all discrete inputs and outputs for the upgraded system. The ControlLogix platform integrates natively with the Kinetix drives over SERCOS, simplifying motion programming and enabling unified fault diagnostics across the control system.

PanelView Plus HMI

An Allen-Bradley PanelView Plus touchscreen was integrated into the system, providing operators with a clear, modern interface for monitoring servo status, acknowledging faults, and accessing operational parameters. HMI screens were reviewed with the client prior to final installation, with requested modifications incorporated before commissioning.

Panel Backboard & Power Infrastructure

All control components — Kinetix drives, ControlLogix PLC, I/O modules, and supporting hardware — were mounted and wired on a new Hoffman electrical panel backboard, delivered ready for installation. The client's electrical contractor handled removal of the existing 240V transformer and installation of a clean 3-phase, 480V, 70-amp supply to support the new servo hardware.

The servo motors and drive components were specifically sized for the MK2 Backfold's full design throughput of 30,000 cartons per hour — ensuring the upgraded system meets production demands from day one without compromising on speed or precision.

Technology at a Glance

Commissioning & Startup

Prior to any programming work, LCS conducted a detailed review of the backfold operating sequence with the client, documenting the approved logic as the basis for PLC and motion programming. Commissioning activities included:

• Electrical I/O checkout — verifying all wiring, drive connections, and safety circuits against the AutoCAD schematics
• SERCOS network validation — confirming drive discovery, axis configuration, and real-time communication between the ControlLogix and Kinetix drives
• Servo tuning — velocity and position loop tuning for both axes to achieve target motion profiles at full production speed
• Motion sequence testing — step-by-step verification of the backfold cycle, including timing, position targets, and fault response behavior
• HMI screen walkthrough with operators, covering normal operation, alarm acknowledgment, and parameter access
• Operational training for client personnel on the new control system, covering startup procedures, routine operation, and basic troubleshooting

Results & Impact

The MK2 Backfold servo upgrade restored full production capability on the North packaging line and delivered a modernized, maintainable control platform:

• Legacy end-of-life servo system replaced with a current-generation Allen-Bradley platform, eliminating spare parts risk and restoring vendor support coverage
• Servo motors and drives sized and commissioned for 30,000 cartons per hour, meeting the line's full design throughput requirement
• SERCOS motion network provides high-speed, deterministic servo synchronization suited to the demands of high-volume carton forming
• PanelView Plus HMI gives operators clear visibility into servo status and fault conditions, reducing reliance on specialized legacy system knowledge
• New AutoCAD electrical schematics delivered with the panel provide accurate as-built documentation for future maintenance and troubleshooting
• Standardized Allen-Bradley platform aligns the MK2 Backfold controls with the broader Allen-Bradley ecosystem, simplifying cross-training and spares management

About Logic Control Systems

Logic Control Systems (LCS) is a Texas-based industrial automation integrator specializing in PLC programming, SCADA/HMI development, process control, electrical panel fabrication, commissioning, and remote automation maintenance. LCS serves clients across the U.S. in industries including food processing, fabrication, chemical, oil and gas, pharmaceutical, and water/wastewater.

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