Projects | Motion Tronic

183KW Servo Motor Rescue in Record Time

MotionTronic — Tue, 24 Jun 2025 06:09:42 +0000

When production is critical and every minute of downtime costs thousands, you need a partner who can deliver fast. That’s exactly what happened when a South African automotive manufacturer experienced a sudden breakdown on a vital piece of equipment.

At Motion Tronic, we recently responded to an emergency involving a 183KW Baumüller servo motor, the powerhouse behind the main extrusion screw of a large plastic injection moulding machine used to produce car parts. This wasn’t just any component, it was at the heart of a high-throughput production line, and any delay would mean massive operational and financial setbacks.

The Problem: A Rare Bearing Failure

Our team immediately stripped and assessed the motor. The fault? A failure in the non-drive end bearing. But not just any bearing, this one was fully insulated, designed specifically to protect against the flow of electrical currents through the bearing. This insulation prevents electrical erosion and extends the motor’s lifespan, especially in high-performance applications.

The challenge? This bearing isn’t stocked locally due to its specialised design. With time ticking and no alternative available in South Africa, we needed a solution fast.

The Solution: Global Sourcing + Local Expertise

Thanks to our extensive supplier network and close ties with European manufacturers, we arranged for the correct insulated bearing to be flown in directly from Germany without delay.

While we awaited its arrival, our technicians prepped the motor for reassembly. The bearing housing was re-sleeved, and the rest of the motor underwent a full service and inspection to ensure it would return to the customer in like-new condition. Fully aligned to manufacturer specifications.

Once the part arrived, our team worked quickly to complete the reassembly and reinstall the motor on-site, ensuring the machine was back up and running by the following Monday morning.

The Outcome: Downtime Minimised, Production Restored

Our client avoided what could have been a prolonged production stoppage thanks to Motion Tronic’s commitment to speed, precision, and reliability. This emergency repair is a perfect example of how we pull out all the stops when our customers need us most. Even sourcing rare components across continents to get the job done.

Encoder Alignment Success in Uganda’s Bottling Industry

MotionTronic — Mon, 11 Nov 2024 09:43:10 +0000

Our commitment to minimising downtime and maximising productivity is at the core of every project we undertake. Recently, we were called to perform an urgent repair on a critical injection moulding machine in the bottling industry in Uganda. One of the largest bottling companies in the region was experiencing a breakdown, putting production on hold and adding pressure to resolve the issue promptly. This wasn’t just about fixing a machine; it was about getting a major industry player back on track with minimal delay.

Meeting a challenge with expertise

Upon arrival, we assessed the situation and determined that an encoder alignment was needed to restore the machine’s functionality. This essential component directly affects precision in automated systems, and misalignment can lead to severe inaccuracies and, ultimately, downtime. We recognised the urgency and set to work straight away, focusing on a solution that would bring the machine back to optimal operation in record time.

The complexity of this breakdown called for both expertise and agility. After performing a motor repair and realigning the encoder, we worked in close coordination with the machine agents to recalibrate the system. This critical final step ensured that the equipment met the precise specifications required to resume high-volume bottling production.

Rapid response for successful outcomes

The entire process—from the moment we landed in Uganda to the completion of repairs and recalibration—took less than 48 hours. This fast turnaround meant our client could resume production swiftly, avoiding further losses. Our team’s dedication to precision and efficiency played a crucial role in achieving this outcome, reflecting our core mission at Motion Tronic: providing industry-leading technical solutions with minimal disruption to our clients’ operations.

Minimise your downtime with us

Projects like this underscore our commitment to delivering fast, reliable service to clients worldwide. At Motion Tronic, we understand that downtime can have a ripple effect across a company’s operations and the supply chain as a whole. That’s why we prioritise swift, high-quality repairs and preventative measures to keep our clients up and running.

Energising Swaziland: Motion Tronic’s Personal Touch in DC to AC Extruder Upgrade.

MotionTronic — Mon, 25 Sep 2023 12:19:54 +0000

In the fast-paced world of industrial automation, staying ahead of the curve isn’t just a choice; it’s a necessity. Motion Tronic has become synonymous with innovation in automation and control solutions. We recently embarked on a remarkable project showcasing our expertise and unwavering commitment to client success. Join us for a look behind the scenes as we undertook an extraordinary DC to AC extruder upgrade for a Swaziland-based company. We’ll uncover the challenges we faced, the ingenious solutions we crafted, and the resounding success we celebrated, all with a personal touch.

With a legacy spanning over two decades, Motion Tronic has become a trusted partner in the automation industry. Our specialisation lies in delivering cutting-edge control and automation solutions, and our reputation is built on excellence and dependability. What sets us apart is our knack for tackling intricate projects, customising solutions to cater to unique needs, and ensuring that new technology seamlessly integrates into existing systems. In short, we’re not just experts; we’re your partners in progress. And we never sidestep a challenge.

The Challenge: A Swaziland Upgrade Picture this: an outdated 110KW DC drive and motor system in dire need of a revamp and a company in Swaziland eager for a transformation. The mission was crystal clear – replace the obsolete with something more efficient and dependable.

The Extruder

The Personal Solution: A Customised Answer. At Motion Tronic, we don’t believe in one size fits all. We rolled up our sleeves and set to work, meticulously designing and constructing a top-of-the-line control panel. This panel was to be the heart of a new 110KW AC drive, accompanied by a specialised AC motor complete with forced cooling and encoder feedback. Every detail was crafted with care, ensuring precision and uncompromised quality.

The Control Panel

The Human Touch: People Do Business with People. Once the panel was ready, it was time for the personal touch. Motion Tronic didn’t just deliver the hardware; we dispatched a dedicated technician to the customer’s site in Swaziland. Why? To ensure a seamless transition from the old DC system to the new AC system, to make sure the client felt supported every step of the way.

The Motor

Commissioning, Connection, and Celebration. The commissioning process was no small feat. It involved reconfiguring the control signals that were initially connected to the DC drive, aligning them flawlessly with the new AC drive. This meticulous rewiring was all about preserving the system’s functionality, just as it was in the previous setup.

Testing followed, and the results were triumphant. In a surprisingly short span, the new AC extruder drive system was up and running at full throttle. The machine roared back to life, and that very evening, the client resumed production.

The Legend Plate

Motion Tronic: Where Expertise Meets Heart. Motion Tronic’s DC to AC extruder upgrade story isn’t just about technical prowess; it’s about the personal touch we bring to every project. As the industrial landscape continues to evolve, clients can rest assured that we aren’t just partners in automation; we’re partners in progress. Motion Tronic will remain a mainstay and a trusted ally in innovative automation and control solutions.

Motion Tronic consists of four divisions to ensure you get the very best, specialised industrial automation solutions. These include projects, technical support, repairs, and agencies. Our commitment to excellence consistently delivers results across industries. Make Motion Tronic your partner and explore a space where precision and performance intersect.

For more information on our suite of services and customised solutions, visit our website or contact us today. With Motion Tronic, you’re not just automating; you’re orchestrating achievement.

Drive Testing Capabilities of Our New Electronics Workshop

Then and Now: Motion Tronic Since the 2021 South African Unrest

Introducing Motion Tronic’s MD800: The Compact AC Multidrive for South African OEMs

The post Energising Swaziland: Motion Tronic’s Personal Touch in DC to AC Extruder Upgrade. appeared first on Motion Tronic.

Upgrade of Mechanical Equipment with Enhanced Electronics for Silveray Stationery Company

MotionTronic — Mon, 04 Sep 2023 12:00:29 +0000

Motion Tronic recently partnered with Silveray Stationery Company to streamline their booklet production system with the aim of reducing future maintenance costs, ensuring precise paper ejection, and ensuring control of the entire system is user-friendly. Explore this project below to discover how we used cost-effective Inovance industrial automation solutions to achieve these outcomes and more for our client.

Project Overview

Motion Tronic set out to upgrade the existing mechanical equipment with advanced electronics, specifically integrating servo and motion control, to simplify maintenance and enable more precise, streamlined control of the entire operation. The system was built using Inovance equipment, including PLC, Servo motor, servo drive, VFD, and HMI.

Booklets evenly distributed and synchronised

Motion Tronic’s Role

– Electrical Design

We developed comprehensive electrical drawings to seamlessly integrate the new electronics with the production line’s existing components.

– Mechanical Integration

We collaborated with the mechanical team to successfully integrate the upgraded electronics.

– Software and HMI Graphics

We designed a custom software system and intuitive HMI graphics for simplified operation and monitoring.

Complex gearing and pullies to eject the paper all powered by an Inovance Servo motor

Project Technical Details

Motion Tronic streamlined future maintenance costs by making use of the cost-effective Inovance brand. Our approach involved incorporating a servo motor controlled through pulse control input, ensuring precise paper ejection. An intuitive Human Machine Interface (HMI) was implemented, allowing seamless system control and facilitating adjustments in speeds and timer settings as needed.

The Variable Frequency Drive (VFD) operation was efficiently managed using Modbus, enhancing fault retrieval and providing timely status updates. To further improve fault detection and accessibility for maintenance, the upgraded system was now accommodated in a larger enclosure, making it easier to detect issues and carry out necessary maintenance tasks.

Objectives Achieved

Enhanced Maintenance

The upgrade simplified future maintenance through reliable Inovance components.

Precise Operation

The integration of servo and motion control ensured more accurate paper ejection.

Cost-Effectiveness

By utilising cost-effective Inovance components, the project optimised costs for the client.

User-Friendly Control

The intuitive HMI interface allows for easy adjustment of system parameters.

Enhanced Monitoring

The use of Modbus facilitates efficient monitoring of VFD faults and status.

Improved Accessibility

The larger enclosure improves fault identification and maintenance convenience.

Inovance VFD driven conveyer for movement of booklets

This project is a perfect example of how Inovance offers the technology to solve challenges throughout the production process. We were proud to have assisted Silveray Stationery Company with these bespoke technological interventions, designed specifically for their systems and within their budget. Please contact Motion Tronic if you’d like to enquire about how our automation solutions can help your business become more efficient, productive and profitable.

The post Upgrade of Mechanical Equipment with Enhanced Electronics for Silveray Stationery Company appeared first on Motion Tronic.

Can Automation Reduce Energy Costs?

MotionTronic — Thu, 15 Dec 2022 09:34:56 +0000

Yes. Automation is able to reduce energy costs by 10 – 30%, according to the International Energy Agency. Automation shines when used to reduce a factory’s energy consumption, and this has a positive impact on more than just the energy bill. In this article, we unpack how much energy global industry uses, how automation is able to reduce energy consumption, and energy-saving drives that are already improving the South African industrial sector.

The energy demands of industry

Global industry consumes a staggering 40% of global energy supply. It makes sense, given that everything we use in our lives, from clothing to fast cars and everything in between, take huge amounts of energy to produce. As the energy needs of society increases, more and more people are looking to industry to curb their high power consumption with energy-saving technologies and processes.

4 ways automation reduces power consumption

Optimised energy consumption
Automation solutions can regulate and optimise the energy consumption of drives, pumps, and other pieces of process equipment.
Optimised energy output
Likewise, automation can optimise the energy output of equipment, ensuring that no energy is going to waste unnecessarily.
Reduced equipment downtime
By monitoring maintenance markers in real time, automation allows for early fault detection and therefore less stopping and starting of equipment.
Improved productivity
By minimising or fully removing the need for human input, fewer mistakes are likely to be made, resulting in less wastage and less energy consumed.

Energy saving drives improving the industrial sector

Inovance is an automation brand pioneering automation solutions that are as energy-efficient as they are effective. Inovance brings energy-efficient low voltage multidrive products to the automation table. They prefer to use modular designs, making multidrive products that are high performance, high security and high protection rating – while also reducing the manufacturing plant’s energy consumption.

Reduce your energy costs with Motion Tronic

Installing variable frequency drives not only reduces energy costs, but can significantly contribute to improving process control and reliability, increasing production capacity, reduce maintenance costs and lower reactive power. All of these are absolute game-changers for any industrial operation, and sets them up for success as we move further into the 4th Industrial Revolution.

Motion Tronic leads the way as an industrial automation solutions provider in South Africa. We have the pleasure of being sole agents for Baumuller, Microsonic, Servo Mold and Inovance automation products. Contact us to discuss how we can improve your industrial processes with energy-saving automation components from the best brands in automation.

Can Industrial Automation Improve Productivity In Production Lines?

MotionTronic — Mon, 15 Aug 2022 06:20:22 +0000

The answer to this question is a resounding yes! Improved productivity is one of many tangible benefits you can expect when automating your production lines. With the 4th Industrial Revolution (4IR) already in full swing, the best time to consider simplifying your manufacturing processes with automation is right now. In this article we define industrial automation, we reveal how automation works in production lines, and we explain how this can bolster your manufacturing plant’s productivity.

Industrial automation defined

Industrial automation can be described as the control of processes and machinery by autonomous systems using powerful software, meticulous sensors, detailed interfaces, capable robotics and other technologies leading the 4IR.

Optimising of production lines

A project we completed a few months back is the perfect example of how an existing production line can be enhanced with 4IR technologies. We upgraded an old W&H tuber with Baumüller and Invertek automation solutions, achieving two outcomes for our client: Minimise machine downtime & reduce energy costs. Here’s what we did:

Servo Drives & PLC

We used the Baumüller bmaXX5000 series servo drives, along with the Baumüller PLCmc, as part of this project. Perfect control was achieved using an EtherCat network, and active mains rectifiers were installed on tension axes to push power back into the grid for other motors to utilize.

Where position control wasn’t needed and a variable speed drive would do the job, Invertek P2 VSDs over EtherCat were deployed. Remote push button stations were replaced with EtherCat versions of the same brand. The project comprised of 143 EtherCat nodes in total, all communicating at lightning-fast speeds.

Motors

The existing paper tuber system’s two main motors were swapped for the Baumüller DS series motors. These two motors control the length of the finished product and the adjustment of a variable length knife.

We achieved synchronous operation through Baumüller function blocks, coming standard with the Baumüller PLCmc. This small package PLC runs in the microsecond processing range, making it perfect for multi-axis synchronous motion control applications.

Read the full project description here.

How improved productivity is achieved

We’ve identified numerous ways in which automation improves productivity in the production line, and we’re unpacking three of them below:

Increase manufacture output

Saving as much as a few milliseconds at different points in your production line could end up increasing how many products you produce in a given time.

Reduce manufacture errors

Human input and machine malfunction often lead to wastages during production. Automation applications reduce the need for human interaction in the production line.

Increase employee productivity

With less human interaction throughout the production process, employees are made more productive by having more time to perform other workplace functions.

Can pump monitoring in the drive increase machine life?

Industrial automation solutions in South Africa

Motion Tronic is a preferred South African industrial automation specialist based in Durban, KwaZulu-Natal. Our process automation solutions come from the global leaders of the industry, including the likes of Invertek, Baumuller, Microsonic, Servomold and Inovance. We specialize in creating, enhancing, and maintaining production line automation solutions. Get in touch to discuss how we can boost your factory’s productivity, saving you both time and money while improving your bottom line.

The post Can Industrial Automation Improve Productivity In Production Lines? appeared first on Motion Tronic.

Air Extraction System

MotionTronic — Fri, 10 Jun 2022 07:28:29 +0000

Motion Tronic Projects was approached to assist in designing and building a control system to balance the airflow from two ovens through a single extraction fan.

The extraction system is used to extract hot fumes from the main oven on the line. An existing extraction fan driven by a variable speed drive was used to extract the hot fumes through a filter system and exhaust the filtered air to atmosphere. The need for a second oven on the same extraction system called for the air draw from each of the ovens to be controlled to maintain production parameters. A Siemens S7 PLC with 4-inch HMI was sufficient to get the job done. The distance between the field devices and the control was approximately 150m away from each other calling for an initiative solution to be implemented. We achieved a reliable link between PLC and remote panels maintaining the ProfiNet protocol across the factory. We also implemented continuous flow monitoring to measure and ensure the performance remained within the operating parameters.

Controls And Automation

For all your control and automation queries please feel free to reach out to us

The post Air Extraction System appeared first on Motion Tronic.

Project: Material Handling System

MotionTronic — Wed, 08 Jun 2022 06:54:14 +0000

Our customer has asked Motion Tronic Projects to assist them in automating their material handling system with a cost-effective SCADA and PLC combination. We designed, built, and installed a control system that can accommodate the controlling of blower fans, rotary feeding valves and divertors to be able to move product seamlessly by push of a button on the SCADA.

This exciting project gave Motion Tronic Projects an opportunity to show off our skills on SCADA graphics and programming. The system is using a Siemens PLC communicating over ProfiNet to the SCADA server with Weidmuller U-Remote IO in the field over ProfiNet and Invertek VSD’s for the rotary valves.

Buffer Feeding System

The priority buffer feeding system was implemented to give some buffer tanks higher priority than the others. This ensures the high priority lines do not stop and wait for product. Both buffer and silo system come with automatic purging and level control for over fill safety and interlocking. The system automatically switches the system over to the buffer tanks that call for product.

Silo Feeding System

The silo system is a semi-automatic system that depends on the operator input selection of which silo he wants to transport product to. Low level detection on the bag hopper for safety to ensure the system stops if there no product in the hopper. The silo’s have load cell weight indication on the SCADA which gives the operator actual mass of product in the respective silos.

For all your material handling automation queries please feel free to reach out to us at (031-701 1620).

The post Project: Material Handling System appeared first on Motion Tronic.

200kW Invertek Drive Installation – Extruder Application

MotionTronic — Mon, 08 Mar 2021 11:08:06 +0000

Recently, Motion Tronic have acquired a new agency for VSDs. Although this was exciting news on its own, we were extremely excited to be able to install a powerful Invertek VSD, as a way to kick-off this new chapter and begin our journey with another exceptional product manufacturer.

We are now the official agents of Invertek products in KwaZulu-Natal and have already made our first delivery and installed a huge 200kW drive for an extruder application.

The build, installation and commissioning of this project were seamless and our customer was left with a solution that was capable of exceeding performance expectations. All Invertek drives carry a 2-year warranty, and clients also have access to a 24/7 free support hotline, should they require technical support telephonically.

In factories and industries relating to metals, polymers, concrete, ceramics, food products and modelling clay, extrusion is quite a common process and involves pushing materials through a die. The process can be quite a demanding one, requiring a lot of force to push either hot or cold materials through the desired die.

The powerful (0.75 – 250 kW | 1 – 350 HP) P2 Optidrive is an easy to use VSD that is designed for high performance and was a perfect fit for the client’s needs. It provides sensorless vector control for all motor types, some key features include:

Simple PLC functionality
Built-in EMC filter
Low ambient operation (-10°C)
Dedicated hoist mode
Integral brake resistor
Safe torque off

Some other exciting applications for a high-performance VSD, like the P2 Optidrive, include agriculture, cranes & hoists, general automation, mining and more.

Invertek products are real game-changers at the right price point! To find out more about this exciting brand of VSDs, contact us on 031 701 1620 or email Email us.

The post 200kW Invertek Drive Installation – Extruder Application appeared first on Motion Tronic.

December Projects Case Study

MotionTronic — Mon, 18 Jan 2021 12:29:22 +0000

We were keeping busy during the past December shutdown period, installing a turnkey solution and control upgrade. The control upgrade solution, which was fabricated and tested towards the end of last year, was ready for the shutdown period to finish installation and integration into the existing plant.

The solution involved replacing the existing Mitsubishi FX PLC with a new Mitsubishi iQR PLC. Additionally, a GOT touchscreen was added to the solution to manage the new recipe control. A further barcode scanner was integrated to call an associated recipe, quickly for each cycle. Further data capturing and reporting had been added to the PLC, this data was collected by the plant PLC to record cycle time, sequence number, recipe type, and pass or failure result.

Our Turnkey Solution installation had been running well before the site installation, with complete sign-off. The solution consisted of Siemens PLC & HMI communicating to field IO using IO-Link modules. Motion technology, high-speed counting, RFID & camera systems were integrated to provide a reliable sorting and counting function for our client.

The need to identify, recipe, orientate, count and distribute plastic clips in batches within 8-second intervals was achieved using innovative methods, like carbon fiber 3D printing to reduce the machine footprint and overall cost.

Vibration orientation was implemented for the clips to facilitate transport and handling. The sorting and transportation prepared 100-150 clips per minute for the counting head. The counting motor counted each clip through position control and verified the count with a photoelectric sensor wired to a high-speed input. Using both methods ensured that the count was accurate each time.

This was an exciting project where the use of industry-leading methods and technologies were implemented to create a one-of-a-kind solution. Head over to our news page for other interesting reads: https://motiontronic.co.za/blog/

The post December Projects Case Study appeared first on Motion Tronic.