Cosma

Cosma, an Italian machine builder specializing in automatic sheet metal cold-working equipment for the white goods industry, faced a demanding engineering challenge: design a 70-meter production line capable of running 64 axes at a 15-second cycle time to produce washing machine chassis for a customer in Central America. The line needed to automatically load, cut, bend, and assemble metal sheets ranging from 0.35 to 1 mm thickness, targeting 240 units per hour and 1,800 pieces per shift. Achieving this required a high-performance, unified automation architecture that could handle complex axes interpolation while maintaining precision — without a multi-vendor patchwork that would complicate integration and support.

Cosma partnered with Rockwell Automation to engineer a mono-brand automation platform built around Allen-Bradley ControlLogix® 1756 and GuardLogix® PACs as the primary controllers, paired with Kinetix® 5700 servo drives and MP-Series™ servo motors to manage the 64-axis motion requirements. PowerFlex® 525 AC drives, POINT I/O™ modules, and Stratix™ 2000 unmanaged switches rounded out the hardware layer, all connected over a standard EtherNet/IP network. Programming and configuration were unified in the Studio 5000 Logix Designer environment, which simplified axes interpolation and motor coupling. An RSLinx Gateway and a 6181P industrial PC with a 17" display provided visualization and IT connectivity. MobileView™ 2711T operator panels added mobility, enabling parameter control from the shop floor. The integrated platform connected the production line directly and securely to the end customer's ERP system.

The completed line met its demanding throughput target of 240 washing machine chassis per hour within a 15-second cycle time across 64 coordinated axes. Key outcomes included:

• Scalable machine architecture: customers can shift from simple to complex bending profiles on the same machine without full redesign
• Improved line efficiency: Studio 5000's unified motion and logic environment enables engineers to add CPUs or swap stations by reconnecting power and communication cables alone
• IT/OT convergence achieved: direct ERP integration allows the end customer to manage labelling patterns and cutting parameters from the enterprise system
• 24/7 remote assistance enabled through machine connectivity
• Cosma secured ongoing global technical support from Rockwell Automation for start-up and after-sales services

• A mono-brand automation platform reduces integration complexity and simplifies long-term support — particularly important for OEMs exporting globally.
• Standardizing on a single software environment (Studio 5000) for both motion and logic control directly compresses cabinet footprint and engineering time.
• Building IT/OT connectivity into the machine design from the start, rather than retrofitting it, enables customers to leverage ERP-driven production control.
• Scalable control architecture is a competitive differentiator for machine builders: end customers value the ability to evolve production requirements without full machine redesign.
• Global vendor support infrastructure matters as much as technology specs when commissioning lines in remote or international locations.