Press release
Control Techniques
For immediate release
Contact: Katie OWEN
katie.owen@emerson.com
COMMANDER SK DRIVES KEEP CINEMA TRAILERS & ADS ON SCHEDULE
When cinema-goers settle down to watch a feature film, this is always preceded by trailers of
forthcoming attractions and advertisements. What they probably don’t realise is that each such
commercial presentation is carefully worked out to be relevant to the target audience and is
changed weekly at each screen and each cinema throughout the UK. This massive logistical task is
the responsibility of one company based in Slough – Bucks Laboratories – and the special purpose
machines for the editing task, designed and built by the company, all feature intelligent AC drives
from Emerson Control Techniques.
“Control Techniques was instrumental in us winning this prestigious contract,” comments managing
director David Buck. “The reliability and flexibility of the drives – with their in-built PLC functionality was crucial to us. We simply could not have achieved this without Control Techniques!”
Bucks Laboratories, an established film processing laboratory serving the UK film industry, has an
extensive engineering capability, with a reputation in the market for upgrading and re-engineering
equipment for both positive and negative processing – and film copiers / printers as well . “We use
the on-board PLC processing of both Unidrive SP drives and Commander SK AC drives to bring
older, mechanically sound machines to the standards required in today’s market,” explains
engineering manager Graham Greenfield. “The drives’ capabilities eliminate the need for an extra
PLC and they communicate directly with our PC and touch-screen interface, which has the same
control ‘buttons’ as the old machine controller to provide a straightforward changeover to our updated machines. So we are used to using the intelligence of Control Techniques’ drives to the full.
We use Control Techniques drives for many applications exclusively throughout the company and
have never had a failure in over 13 years!”
So, when the company had the opportunity to take on the ambitious UK-wide contract for
advertisements for cinemas, Graham Greenfield felt confident that, using the capabilities of Control
Techniques Commander SK AC drives, they could build the machines needed for the tasks – with
an initial deadline to meet of just three weeks!
Control Techniques, Unit 79 Mochdre Industrial Estate, Newtown, SY16 4LE, UK
T: +44 (0) 1686 612000, F: +44 (0) 1686 612999
e-mail: controltechniques@emerson.com www.controltechniques.com
Press release
Control Techniques
“We conceived unique machines to provide fast, reliable and easy-to-control editing of the filmreels”
says Graham Greenfield.
“We call them ‘White Winders’ because of the melamine board
construction of the editing desks. Each uses Commander SK’s for both drives and overall machine
control too, utilising their in-built PLC capability. The design is simple, elegant – and it works!”
When the company initially won the contract, Graham raced against time to produce the first
machines, which were operated manually with foot-pedal control. As time went on, he was able to
introduce more sophisticated control, including automatic recognition of film joins using ultra-sonic
attenuation sensors that allow the film to be stopped with millimetre accuracy and very precise
tension control.
“Film is heavy,” he explains. “There is a lot of inertia in the reels, so stopping a film from 1,000
ft/minute speed very quickly requires very precise control to prevent breakage or, worse, ending up
with a pile of film on the floor.” The take-up drive determines the speed, in closed loop mode with
feedback from a diameter sensor, using PID control to keep film speed constant between edits. The
feed drive controls the torque, with a spring-loaded dancer control feeding back a 1-10V signal to
the drive. For each edit, the operator determines which join on which to stop. The take-up drive
counts the signals from the ultrasonic thickness sensor and initiates a stop signal that
simultaneously ramps down both drives whilst maintaining precise tension control and stops the film
to within one millimetre accuracy.
Since film has 16 frames/ foot, 64 perforations /foot, this
effectively gives exact position control of the film to allow the operator to carry out the appropriate
action specified on the work-sheet.
Conservatively dimensioned Emerson Leroy Somer motors ensure that slippage is eliminated.
The winders can be used in four basic modes, feeding from the top or bottom of either reel and with
a third reel that can be designated to run as either feed or take-up if required. This means that each
drive has to be capable of performing different roles as needed and is programmed accordingly with
numerous ‘recipes’. The operator’s control simply designates duty to each drive by code number
that selects the appropriate programme.
“Because the real-time response is carried out in the drive, it is so much faster,” comments Graham
Greenfield. “I like the flexibility of these drives with on-board processing, including PID control which
is standard – on many drives this is extra. It means that there’s no additional PLC required, even
though the Commander SK is marketed as a general purpose drive.”
Control Techniques, Unit 79 Mochdre Industrial Estate, Newtown, SY16 4LE, UK
T: +44 (0) 1686 612000, F: +44 (0) 1686 612999
e-mail: controltechniques@emerson.com www.controltechniques.com
Press release
Control Techniques
“In reality, it’s very powerful, very intelligent and keeps the cost of each machine down and our costs
competitive.
You can’t buy something like our white winders off the shelf.
Every bit of their
functionality is done by the SKs.”
Bucks Laboratories now has a total of 18 white winders. Each has one 0.37 kW, one 0.75 kW and
one 1.1 kW Commander SK drives, complete with LogicStick and no additional I/O or special plug-in
modules are needed. Graham Greenfield carried out all of the programming.
Bucks Laboratories’ cinema contract is complex. There are two reels for each cinema screen, one
at the cinema and the second at Bucks for preparation – cutting, inserting and changing content
order. Thousands of reels have to be completed and delivered in time for the weekly changeover.
In addition, Bucks Laboratories holds the national stock of cinema advertisements and Graham has
written the stock control programme too! Currently, some 70% of UK cinemas still use film for
trailers and advertisements, although the trend is to digital – and Bucks Laboratories provide this
service too.
The Commander SK range of general purpose drives – 0.25 to 132 kW - has been designed as a
simple, compact, cost-effective AC motor speed controller that delivers performance with simplicity
and ease of use. With all the parameters needed for 90% of applications printed on the front of the
drive, Commander SK ensures installation and commissioning are straight forward.
However, for more demanding applications as in this case, Commander SK can deliver advanced
functionality at no added cost to the base drive itself. Plug-in options, dynamic performance, PLC
functionality, feedback versatility and connectivity with all main industry networks ensures that, in
more complex applications, Commander SK delivers much more than the average general purpose
drive - giving users lower cost solutions and better productivity in their motor control applications.
Bucks Laboratories, started by David Buck in 1975, employs 80 people at its Slough facility,
produces over 100 million feet of film per year and works for all the major film distributors and many
film makers. It is the only independent, privately-owned picture processing laboratory in Europe.
The company prides itself on its use of cutting edge technology to streamline production and keep
competitive in today’s ultra-demanding market. Bucks Laboratories has identified several niche
markets over many years, has identified market needs and has geared up to dominate each new
market. Recently, the company won the Slough Chamber of Commerce Innovation Award for its
use of technology (Control Techniques drives) – and then went on to win the regional Award too. As
Mr Buck says, “We couldn’t have done it without Control Techniques!”
Control Techniques, Unit 79 Mochdre Industrial Estate, Newtown, SY16 4LE, UK
T: +44 (0) 1686 612000, F: +44 (0) 1686 612999
e-mail: controltechniques@emerson.com www.controltechniques.com
Press release
Control Techniques
Notes to the Editor:
About Control Techniques
Control Techniques, an Emerson Industrial Automation company, is a world leader in the
design, production and marketing of electronic variable speed drives for the control of
electric motors. Our strategy is to concentrate on delivering drives and servo products
that enhance the productivity of our customer’s machines and processes.
We operate through a global network of Drive Centres and Application Centres that both
distribute product and add value by building our drive products into custom designed
systems and by offering the highest levels of customer service.
Our Control Techniques Drive Centres also provide us with invaluable feedback and
market intelligence so that we can further improve our products and service. This
customer focused strategy will enable us to continue to grow profitably.
Our competitive edge is based on our unique focus on drives, our strength in research
and development, our investment low-cost manufacturing and an effective worldwide
marketing strategy.
For the best in drives information visit our website: www.controltechniques.com
About Emerson Industrial Automation
Emerson Industrial Automation, a business of Emerson, is a global technology provider
that enables productivity, efficiency and quality gains for customers across a spectrum of
industries. Our products include alternators, electric motors and drives, electrical
distribution devices and mechanical power transmission, fluid automation and ultrasonic
joining solutions. Emerson brands include Appleton, ASCO, Branson Ultrasonics,
Browning, Control Techniques, Kop-Flex, Leroy-Somer, McGill, Morse, Numatics, OZ/Gedney, Rollway, SealMaster, and System Plast. For more information, visit
www.EmersonIndustrialAutomation.com.
About Emerson
Emerson (NYSE:EMR), based in St. Louis, Missouri (USA), is a global leader in bringing technology
and engineering together to provide innovative solutions for customers in industrial, commercial, and
consumer markets through its network power, process management, industrial automation, climate
technologies, and appliance and tools businesses. Sales in fiscal 2009 were $20.9 billion. For more
information, visit www.Emerson.com.
For editorial information contact:
Katie Owen, Press Officer, Control Techniques Ltd, Drive Centre Marketing,
Ty Rheoli, Unit 79 Mochdre Industrial Estate, Newtown, Powys SY16 4LE
Tel: 01686 612900. Fax: 01686 612999. katie.owen@emerson.com
Control Techniques, Unit 79 Mochdre Industrial Estate, Newtown, SY16 4LE, UK
T: +44 (0) 1686 612000, F: +44 (0) 1686 612999
e-mail: controltechniques@emerson.com www.controltechniques.com