Sen Fung Cold Roll Forming Machine Breakdown – Mitsubishi FX3U-32N PLC, GX-Developer Programming Software
Soft Control responded to a breakdown support request for a Sen Fung Cold Roll Forming machine that had stopped operating automatically.
Upon arrival, our engineers connected to the Mitsubishi FX3U-32N PLC and began diagnostics. The PLC and HMI had been configured for a different machine setup, resulting in sections of unused code. A fatal error had caused several registers to fill with extremely large values, disrupting calculations and halting production.
We cleared key registers and restored the machine’s automatic functions.
During post-repair testing, inconsistencies were noted in the sheet lengths. Further investigation revealed the inverter’s slowdown feature was not activating. We updated the code to resolve this issue, enabling consistent production. However, lingering errors in the PLC logic meant calculation problems persisted. To maintain accurate sheet dimensions, a correcting factor was introduced.
Due to urgent production needs, the machine was returned to service. We also supplied the customer with a quotation outlining recommended upgrades for long-term reliability.
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