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Project Examples

The following examples are intended to show familiarity with specific automation areas of expertise and product brands. Due to the confidentiality requirements of most of the referenced projects, specific detail have been left out. The common point of all the automation areas listed below is the industrial control system. The design and development of industrial control software and systems is what we specialize in.

The following is an index of the listed project examples by project type. Click on a project type to review the example. Click on ^ BACK ^ to return to the Project Examples Index.

PROJECT EXAMPLES INDEX
Machine Control (Simple)
Machine Control (Advanced)
Process Control
Material Handling
Robotics
Vision
Test & Measurement
Validation
Web Enabled Control
Data Collection
Data Processing
Motion Control

Machine Control (Simple):. . .^ BACK ^

REQUIREMENT:A master control program was required for a new contact insertion machine. The machine had no proximity sensors or switches to detect the state of the mechanical components. A start / stop pushbutton input was to be the only machine control. Customer supplied a sequence of operation specification. Customer also requested that the Omron product line be used in the final implementation.
HARDWARE:

The Omron CPM-1A micro PLC was selected to be the machine controller.

SOFTWARE:

Omron CPM-1A Program coded using Omrons' SYSWIN Ver 4.0 application software.

COMMENTS:CPTI designed the program so that the machine builders could make changes to the control sequence without having to know how to write PLC programs.

Machine Control (Advanced):. . .^ BACK ^

REQUIREMENT:A major manufacturer of aluminum tubing acquired a 1950s vintage aluminum extruder, an induction billet heater, and a tubing conveyor / cutter. The requirement was to provide a control system that would operate each unit while also allowing all three units to work together.
HARDWARE:

Two Omron C200HS PLCs with digital, analog, thermal, remote I/O,DeviceNet, and Control Linkcapability were used to control the extruder, billet heater, and conveyor/cutter.
The servo indexers used wereCompumotor 6250 Controllers.
The HMI for the extruder was an Omron NT620C touchscreen.
The HMI for the billet heater was an Omron NT600S touchscreen.
The HMI used for the cutter was a TCP PCjr Touchscreen

SOFTWARE:

Omron PLC Program coded using Omrons' SYSWIN Ver 4.0 application software.
Compumotor Motion control program coded using Compumotors Motion Architect 6000 Series software.
Omron Touchscreens programmed using Omron NT Support Tool software.
TCPTouchscreen programmed using TCP QuickPanel software.

COMMENTS:The original control system components were removed when we received the project. We analyzed the remaining hydraulic, power, and cooling systems. We designed a modular and distributed control system that allowed each unit to operate independently as well as integral part of the resulting manufacturing cell. The design of the main ram speed control resulted in a 9.4 fold increase in precision.

Process Control:. . .^ BACK ^

REQUIREMENT:A major manufacturer of wood products required a control system that would operate a newly acquired pulp processor. Existing motors, contactors, and detectors would have to be used. The system consisted primarily of 17 axes of motor / servo control and a nuclear level measurement system.
HARDWARE:

AnAllen Bradley SLC5/05 PLC with digital, analog, servo, and PLD capability was used as the process controller and motion control platform.
AnEason Technology PC based touchscreen was used as the operator interface.
The level sensing was accomplished with anNRC IndustriesGammatrol II LS-100 Level Switch.

SOFTWARE:

The HMI was developed using Wonderware FactorySuite InTouch software.
ActiveX controls developed inMicrosoft Visual Basic.
The Allen Bradley PLC was coded using Allen Bradley RSLogix500 software.
The operating system used on the Eason Technology PC was Microsoft Windows NT.

COMMENTS:The control system was designed to not only control the 17 motors and drives but record, store, and analyze the operating variables per batch. The data collected was used to more precisely control the duplication of the next batch.

Material Handling:. . .^ BACK ^

REQUIREMENT:A material handling equipment manufacturer was in the process of installing a large material handling system at a major air cargo facility. The contractor that originally was suppling the control system was unable to complete the job. The entire project began to stagnate. The major cause of the problem was ineffective control software and a restrictive control hardware design. Our requirement was to come up with a control scheme that would work with existing control hardware, electronics, and in place subsystems. The core components of the existing hardware control system was 63 PLCs and an integrated computer system.
HARDWARE:

The overall facility was controlled by 22 Allen Bradley PLC5/11 thru PLC5/80 PLCs.
A major facility subsystem was controlled by 41 Mitsubishi FX PLCs
Nine Uticor PMD-180 Displays were used to convey equipment status.
Eight AccuSortbarcode scanners were used for product identification.

SOFTWARE:

The Allen Bradley PLCs were coded using Allen Bradleys' DOS based 6200 Series software.
The Mitsubishi PLCs were coded using Mitsubishi MEDOC software.
The Uticor Displays were programmed using PMD-180 programming software.
The Accu-Sort scanners were programmed using Accu-Sorts' programming software.

COMMENTS:After reviewing the situation, we found the material handling equipment to be very well made and installed. We found the control hardware selected to be well suited for the job. We also found the remaining contractors to be competent and flexible. What was missing was a well designed and reliable software control system. The hardware control system was already in place and could not be changed. We designed and developed a modular and distributed software control system based on our OOLL PLC programming technique. Even though our control system design methods and techniques solved the material handling control system problems, we attribute the primary success to the mutual cooperation we were able to obtain between the suppliers, contractors, and the customer.

Robotics:. . .^ BACK ^

REQUIREMENT:Major manufacturer of electrical switches for the automotive industry required a control system that would integrate a pick and place robot with a plastic injection molding machine.
HARDWARE:

The existing pick and place robot was aSeiko TT8800 SCARA Robot and Controller.
The machine master controller was anAutomation Direct DL405 PLC.
The plastic injection molder controller was an Allen Bradley SLC5/03 PLC.
The operator interface was a TCP QuickPanel Jr touchscreen.

SOFTWARE:

Seiko TT8800 Robot Controller was programmed using Seikos' SPEL for Windows software.
The Automation Direct PLC was programmed using Automation Directs' DirectSoft32 software.
The Allen Bradley PLC was programmed using Allen Bradleys' RSLogix500 software.
The TCP touchscreen was programmed using TCPs' QuickDesigner software.

COMMENTS:A specification was developed and agreed upon as to the operation of the final integrated control system. An individual robot control program was produced based on CPTIs IPOsystem design methodology. The robot control program was designed to control the robot as well as its end-effector. A master control program was produced based on the same methodology. The master control program was responsible for overall integrated manufacturing cell operation as well as operator interface. An OOLL module was added to the plastic injection molding machine PLC to allow interface to the master controller. This was accomplished without altering any of the original PLC code.

Vision:. . .^ BACK ^

REQUIREMENT:A manufacturer of high volume plastic part assemblies wanted to reduce the chance of their customers receiving any defective units. Their present method of detection was visual spot checking. They wanted to move toward 100% part checking.
HARDWARE:

The inspection system used was aDVTvision inspection system.
The master integrator/control was provide by aSiemens SIMATIC S7-200 PLC.

SOFTWARE:

The DVT vision system was programmed using DVTs' Framework software.
The Siemens PLC was programmed using Siemens S7-200 Micro/Win programming software.

COMMENTS:The three main issues to be resolved before any vision inspection system can be applied is lens, lighting, and the operating environment. We designed this system to take into account variable conveyor speeds, indirect factory lighting, vibration, resolution, and ease of maintenance.

Test & Measurement:. . .^ BACK ^

REQUIREMENT:A circuit board assembler required a turnkey solution for the "end of line test" of a new electronic product. Tester was to be stand-a-lone, operator friendly, able to be calibrated, and able to perform the steps in the supplied test procedure; limited only by the accuracy of that test procedure.
HARDWARE:

Designed, fabricated, and assembled custom frame and control panels.
Wired, installed, and tested all electronic components and test equipment.
The master controller was aGE90/30 PLC with digital I/O, ASCII Basic, and Ethernet capability.
TheGPIBcapable test equipment was fromAgilent Technologies.
Symbol Technologiesbarcode scanner was incorporated.
AZebrabarcode label printer was used for printing ID/serial number labels.
AnAmerindustrial PC was used as the test control platform.
Two custom PC boards containing the specification loads and test circuits were designed, fabricated, stuffed, and tested.
Two custom test fixtures were design, machined, assembled, and installed to connect theDUTto the tester.

SOFTWARE:

The GE PLC was programmed using GEs' VersaPro software.
The Agilent test equipment was configured using Agilents' Plug & Play Instrument Drivers.
The test sequences were programmed using Agilents' VEE Pro 6 software.
The Zebra barcode printer was programmed using Zebras' ZPL programming language.
The ActiveX controls were developed using Microsofts' Visual Basic.
External special application functions were developed usingBorlands' C++Builder.
The custom electronic circuits and PC boards were primarily developed usingCadencePCB Design Studio.
Circuit simulation was accomplished with Cadences'PSpice A/D.
The fixture design was primarily developed inSolidWorks3D cad software.
Frame and structural design was primarily developed inAutodesks' Mechanical Desktop 6.

COMMENTS:It is our opinion that the definition of a good end-of-line product tester is one that allow the owner of the tester to be responsible for the implementation of the test and not the test itself. As a result, we design this tester to be traceable ultimately toNISTand to the test specification owner. This allow the tester owner to have full control over how the test is implemented and the test specification owner to have full control over what the test is implementing.

Validation:. . .^ BACK ^

REQUIREMENT:A pharmaceutical manufacturer required more extensive functional verification of an existing control system that managed a batch process. In order to gain further control over the quality of their product, continuous feed-back that the control system met original manufacturers specifications during the batch process was desired.
HARDWARE:

The validation controller was a Siemens S7-300 PLC with digital, analog, PC processor, and Ethernet capability.
The validation data acquisition platform was aCompaqdesktop PC.

SOFTWARE:

Siemens PLC was programmed using Siemens SIMATIC Step 7 software.
The the data acquisition program and HMI was developed inNational InstrumentsLabVIEW.

COMMENTS:We designed and installed a process control validation system that was independent of the existing control system. The data collected was used to manage control system operation within the OEMs specification window.

Web Enabled Control:. . .^ BACK ^

REQUIREMENT:A medium size manufacturer of relay assemblies operated out of two locations. The parts used on the final assembly were manufactured at both locations, then consolidated at one location for assembly. A method of linking the manufacturing process at both facilities so that parts produced at the assembly facility drove the production at the other facility.
HARDWARE:

A pair of Omron C200HX PLCs were used as the cell controllers.
The the Omron RFID system was used as the subassembly tracker.
The web link, HMI, and data acquisition platform operated onDelldesktop PCs

SOFTWARE:

The Omron PLCs were programmed using Omrons CX Programmer software.
The web link was coded inHTML/XMLandJava.
The web link was developed usingEditPlusand Borlands' JBuilder.
The web link custom functions were developed in Borlands C++Builder.
The HMIs were programmed using Microsofts Visual Basic.
The operating system used in both cases was Microsofts Windows NT.
The databases were developed usingCorels' Paradox.

COMMENTS:The final assembly consisted of customized subassemblies produced at each separate facility. The build requirements of one facility directed the build requirements at the other. The assembly process was accomplish in a manufacturing cell of which one was located at each facility. We designed and integrated the control systems of each manufacturing cell via the web and an RFID system. As the subassemblies were being built at each facility, information was made simultaneously available at the other facility to drive the decision process for the next assembly step. It was as if both manufacturing cells were merged into one.

Data Collection:. . .^ BACK ^

REQUIREMENT:A large automotive supplier had five 14 year old mechanically intensive assembly machines. Each machine was controlled by a TI500 series PLC. The machine counts, up and down time, faults, and hours of operation needed to be collected without altering the existing assembly process.
HARDWARE:

An existing Compaq desktop PC was used for the data acquisition platform.
The machine controllers in, all five cases, were Texas Instruments TI500 Series PLCs.

SOFTWARE:

The data acquisition program was an ActiveX control developed in Microsoft Visual Basic.
The HMI was developed and displayed using Siemens' WinCC.
The machine controller program data collection modules were programmed using Siemens TISoft software.

COMMENTS:Five individual data collection programs were designed and installed on one PC. All five programs were controlled via a single PC based operator interface. The operators were able to enter job related data and print reports. Collected data was made available for data processing via network bridge to corporate IT.

Data Processing:. . .^ BACK ^

REQUIREMENT:The same large automotive supplier wanted a turnkey software application that, after activating from the windows desktop, could acquire, process, display, and print the results of the data collected from the TI500 PLCs.
HARDWARE:

No hardware supplied for this project.

SOFTWARE:

Three applications developed using Microsoft Excel and Visual Basic.
One application developed using Microsoft Access and Visual Basic.
Remaining application developed usingMandrake LinuxandPHP.

COMMENTS:Each of the five applications were designed for a specific automated reporting purpose. Each application existed on the windows or linux desktop as an icon. When activated, would read the data from the data collection archive, process the data, then terminate. For instance, one of the applications, when activated, would read the data collected from the previous days production runs, determine machine up and downtime, number of good and bad parts run, number and type of machine faults, etc. Then automatically input the processed data into a preformatted Microsoft Excel spreadsheet for analysis and finally print a series of reports for the morning meeting.

Motion Control:. . .^ BACK ^

REQUIREMENT:A medical products manufacturer built a precision multi-station assembly machine. The machine consisted of 11 highly integrated stations. A control system was required to operate the machine.
HARDWARE:

A Siemens S7-315 PLC with digital, servo, and ethernet capability was used as the master control platform.
Four of the servo axes were controlled usingGalils' DMC2040 Controller.
The station controllers were Siemens S7-200 PLCs.
The vision system was developed usingCognexIn-Sight Vision Sensors.
The HMI platform was a Dell desktop PC

SOFTWARE:

The Siemens S7-315 was programmed using Siemens SIMATIC Step7 software.
The Siemens S7-200 PLCs were programmed using Siemens SIMATIC Micro/Win software.
The HMI was developed using Siemens' WinCC.
The Galil servo axis were programmed using EditPlus text editor and Galils DMC Terminal software.

COMMENTS:We designed, developed, installed, and tested a modular and highly distributed multi-vendor control system. The control system consisted of 10 servo axis, 10 camera stations, 12 PLCs, and 2 PCs that controlled 2 welders, 11 stations, environmental components, material handling components, and 6 operator interfaces.

Common Point Technologies, Inc.
P.O. Box 290
Sugar Grove, Illinois 60554-0290
(800)357-2784