Servo Roll Feed Controller Acceptance Checklist
A narrow servo roll feed controller acceptance checklist for I/O, recipes, feed accuracy, encoder checks, alarms, FAT/SAT records, commissioning, and retrofit boundaries.
A servo roll feed controller should be accepted by its I/O list, recipe behavior, feed accuracy, encoder feedback, alarm logic, safety boundary, FAT/SAT records, and commissioning evidence. A controller that looks correct on a quotation can still create production loss if its signals, parameters, and release checks are not frozen before installation.
This page is a narrow support page for servo roll feed controller acceptance in the MaxDo automation topic network. It owns only the controller handoff layer: I/O, recipes, feed accuracy, encoder checks, alarms, safety boundary, FAT/SAT records, commissioning evidence, and retrofit limits. It is not the servo feed positioning architecture matrix and not the main automation system map. For the mechanical and feed-system context, use the servo feed positioning architecture matrix. For line-level automation architecture, use the automated metal processing system map. This page focuses on what the controller must prove at handoff.
Start With the Controller Boundary
The first acceptance decision is boundary clarity. Define whether the controller is responsible only for feeder motion or also for decoiler communication, loop control, shear timing, press signal exchange, recipe storage, safety interlocks, inspection data, and production counts. If ownership is unclear, commissioning becomes a debate between mechanical, electrical, controls, and operator teams.
| Boundary item | Acceptance question | Record to freeze |
|---|---|---|
| Motion scope | Does the controller own feed length, acceleration, correction, and release? | Axis list and motion sequence |
| Signal scope | Which sensors, encoders, guards, and external machines exchange signals? | I/O list and wiring responsibility |
| Recipe scope | Which job fields must operators store, recall, and lock? | Recipe table and permission rules |
| Acceptance scope | Which errors stop the line, hold quality, or require supervisor release? | Alarm matrix and FAT/SAT form |
Freeze the I/O List Before Panel Build
The I/O list should name every signal before the control cabinet is built: feeder ready, start, stop, jog, encoder feedback, material present, loop high/low, shear ready, press request, guard status, emergency stop, servo fault, air pressure, lubrication, quality hold, and production count. Each signal needs a source, destination, normal state, fault state, and owner.
If the controller is part of a retrofit, connect the I/O review to the slitting line control upgrade roadmap. If the project is a broader line automation job, use the metal production line automation execution plan.
Define Recipe Fields and Operator Permissions
Recipe control is where many servo feed projects either save time or create new errors. Define the fields operators can store and recall: material, thickness, width, feed length, batch count, speed, acceleration, correction limit, shear or press timing, loop mode, alarm thresholds, and inspection notes. Then define who can edit, copy, delete, approve, or lock each recipe.
| Recipe field | Why it matters | Acceptance check |
|---|---|---|
| Feed length and correction limit | Controls dimensional output and correction behavior | First-piece and repeat-sample measurement |
| Speed and acceleration | Prevents slip, marking, or unstable loop behavior | Run at agreed production condition |
| Batch and count logic | Protects order quantity and downstream scheduling | Compare HMI count with physical output |
| Permission level | Prevents unapproved parameter changes | Test operator and supervisor access |
Test Feed Accuracy With the Real Release Method
Feed accuracy should be tested the same way production will release material. Record programmed length, measured length, sample quantity, measuring tool, material thickness, surface condition, speed, acceleration, encoder feedback, and correction action. Do not accept accuracy from one perfect sample. Use a repeated sample set and record whether drift appears after speed change, restart, or batch completion.
For CTL lines, map the feed controller to the cut-to-length process station acceptance map. For slitting programs where width and feed behavior interact with material handling, use the slitting width tolerance measurement protocol.
Turn Alarms Into Useful Stop Reasons
Alarm logic should separate warning, controlled stop, quality hold, safety event, servo fault, sensor fault, recipe conflict, and maintenance reminder. Each alarm should show the operator what happened, where it happened, whether production can continue, and what record must be saved. A long alarm list without context does not improve uptime.
For data and event architecture, connect this checklist to Industry 4.0 in metal processing. For setup-time loss caused by recipe or controller behavior, use the slitting line setup time reduction checklist.
Build FAT and SAT Around Controller Evidence
FAT should prove the controller logic before shipment: I/O simulation, HMI screens, recipe storage, permission levels, alarm states, encoder feedback, servo response, and data records. SAT should prove the same logic on the real line with material: first-piece release, repeat samples, stop/restart behavior, safety checks, shift handover, and operator training.
- Attach the final I/O list, electrical drawings, and signal ownership table.
- Record recipe fields, allowed ranges, permission levels, and backup method.
- Measure feed accuracy across first piece, repeated samples, restart, and production speed.
- Test alarms by category: warning, stop, quality hold, safety, maintenance, and servo fault.
- Close commissioning with training records, deviation list, final backup, and sign-off form.
Route Controller Projects to Equipment Paths
After the controller acceptance boundary is clear, route the project to the correct equipment family. CTL feeding and shearing projects should review the metal cut-to-length line category, including CT-850, CT-1350, and CT-1650. Slitting or strip-fed projects should compare the metal slitting machine category, including MA-850, MA-1350, and MD-1650.
To request a controller review, send MaxDo the line type, material range, feed length target, tolerance method, I/O list, current HMI or PLC limits, recipe needs, alarm complaints, FAT/SAT expectations, and commissioning schedule through the contact form.
