SUPPLY OF CONTROL PANEL FOR ROLL FORMING HYDRAULIC PRE-PUNCHING MACHINE
In this project the client’s requirements were to have a cost-effective but efficient control system for a steel rollforming punching machine developed from the ground up. These requirements were catered to in the design and implementation of the complete electrical circuits and PLC & HMI software programs. The system consisted of control of a combination of VSD and servo motor drives, hydraulic and pneumatic solenoid valves, various interfacing sensors providing feedback and the actuation of hydraulic punches with adjustable tooling.
PLC and HMI programs were developed to increase the output, accuracy, and safety of the existing manufacturing operation at the premises, while also simplifying operation for machine operators. In using a high-resolution touch display in conjunction with a Node-RED program for the HMI, features of programming and saving new production routines via this HMI were provided.
Challenges overcame involved programming optimal operation of the numerous hydraulic punches, dependent on a wide range of variables such as their adjustable tooling sets, user-adjustable material feed speeds, while accommodating as wide a possible range of production patterns for the steel feed material. Tenth of millimetre precession was a requirement adhered to, with automatic and manual operation modes, remote online control and monitoring integrated into the final system package.
ELECTRICAL SYSTEM UPGRADE OF A BIODIESEL PLANT
The plant contains numerous storage and reaction tanks which were found to be lacking in level switches and condition alarms, having room for improvement
Our solution package included design, supply and installation of the electrical system upgrade to comply with the latest EPA regulations. The design included electrical and control engineering. Electrical schematics and PLC with SCADA programs were delivered as part of the engineering stage.
Supply and installation was delivered on time and within the planned plant shutdown. Upon installation completion we conducted commissioning and handed over the supplied equipment. Commissioning reports is documentation we typically produce and provide for our clients upon completion of jobs.
REDUCING DOWNTIME RISK
We designed a control system upgrade for deselection of drives in a 3 x 710kW ABB multidrive system.
The upgraded control system now dramatically reduces downtime risk in the event of drive malfunctioning. The control system allows the disabling of drives with a click of a button. Disabled drive can be removed from service while the application can continue operating with reduced capacity.
We managed the entire process from discussion of the upgrade with the client to its commissioning. We developed PLC logic, tested it in the workshop and implemented it into the existing client's PLC.
Main challenges overcome were the dynamic assignment of master or follower roles to the drives on-demand.
CONTROL SYSTEM FOR BELT CONVEYOR
This job involved the design and development of a control system for a belt conveyor. The scope of work for this job included a full range of control system engineering: design of the control system, writing a functional specification, development of the PLC program, development of HMI screens, and testing of the entire system.
The conveyor is driven by a Voith fluid coupling TPXL where we had to develop the control stages of filling the fluid coupling to achieve a smooth conveyor start. We worked with engineers from Voith and they were a great help.
The winch control system requirements weren't typical for a belt conveyor. As per the requirements, the winch operation had to include multiple modes. The range of the modes had to be extended from just automatic and manual to additional LTU fill-in, LTU empty and conveyor retraction/extension modes. To achieve the desired operation of this winch, ABB ACS880 regenerative drive was chosen. We are experts in setting up controls of ABB drives via Ethernet/IP from ControlLogix (or CompactLogix) PLCs, so this was easily achieved.
Overall, in this project there were some unpredicted delays, however, the development, testing and commissioning stages were completed on time.
ADVANCED ROBOTICS FOR SPRING HANDLING
Design and implementation of advanced robotic systems. The goal of recognising springs on a pallet, locating their positions, navigating the robot to pick them up and place them on a conveyor was satisfied
The system includes a control PC, a video recognition system and Yaskawa Motoman robotic arm. We developed a software to interact with the video camera and the robotic arm. An algorithm in the software takes a picture of the pallet and, using an image recognition software, analyses the photo. Calculation of the coordinates of a spring is performed and the robot is sent a command to pick the spring. Before placing onto the conveyor, the PC software defines a spot without a spring and sends a command to the robot for placing it.
TRAIN LOADING SYSTEM*
Development of Control System (PLC and SCADA) for TLO - Train Loading System
Train Loaders are designed to load safely, efficiently and accurately while maximising the use of the capacity in each wagon. There are Volumetric and Gravimetric (Batch) Train Loaders, for any applications that require wagons to be loaded with bulk materials. Train Loaders are easy to use with flexible options for loadout operations. Manually controlled and automated systems are available with the ability to control at local control stations or remotely (on or off site).
* note: this is the company's lead engineer experience, and not the company's achievement.
CONTROL SYSTEM FOR TRANSFER TABLE
Design and commissioning of control system for 32 electric motors. The project's result was a specific and complex pattern for a packaging transfer table with omnidirectional wheels.
We also managed electrical manufacturing process, sourced components and subcontracted an electrical manufacturing company to build the control panels.
NEW CONTROL SYSTEM FOR TUBE BENDER
Design and implementation of new control system based on Siemens S7-1200 PLC for 10 years old HERBER Tube Bending Machine EBM-125TB.
Objective of the project is to replace existing PC/PLC based control system (very outdated) with new series PLC and Linux based PC with User Interface developed in Node-RED. Most of the control interface will be transferred to the Node-RED dashboard and will be presented on a big touchscreen display. However, joystick and some existing pushbuttons on the existing control panel will be reused. Some specific operation actions require hardware buttons due to quicker response, so it will be wired to PLC's digital inputs.
The project is ongoing and more updates are coming.
CONTINUOUS SHOT PEENING
To eliminate downtime and manual labor, we developed a new control system for a refurbished continuous shot peener in a spring manufacturing production line. In combination with a robotic arm this has led to a significant increase in production output.
CONVEYOR EFFICIENCY IMPROVEMENT
Preformed an analysis of a 4300 TPH conveyor system and identified optimisation opportunities to reduce operating costs by over 25% per year. It achieved by reduced maintenance frequency and lower energy consumption.
YASKAWA MOTOMAN ROBOT
We "retaught" a robotic arm from welding to handling operations and updated firmware for complete integration into the production line. Robot's electrical interface has been connected with corresponding PLCs to enable external control. The firmware has been updated for improved performance.
KITAMURA 4-AXIS CNC MACHINE
A client's CNC machine has been out of service for long time. After troubleshooting, we delivered and commissioned a fully functional 4-axis Kitamura CNC machine. During commissioning we set new parameters for all servo drives to control tool changer, spindle and pallet changer.
CONVEYOR MULTI DRIVE SYSTEM (VSD)
Delivered, tested and commissioned new parameters set for a 2.1 MW VSD system. Parameters for the ACS800 ABB system had to be readjusted to meet new equipment requirements.
GENERAL PLC DEVELOPMENT
Programmed and commissioned a variety of PLC systems to meet customer's requirements, most commonly Siemens S7 and AB ControlLogix 5000.
Shot Peener starter
GENERAL TROUBLESHOOTING OF EQUIPMENT
Equipment failure investigations. Rectifying faults by using drawings, electrical schematics and PLC programs. Most of serviceable equipment has been returned to its working condition on the same day.
VSD multi-drive system (common DC bus)
4-axis CNC machine
Designed, programmed and manufactured a VSD monitoring device Bigollo X1. The device connected to the network of Variable Speed Drives. It displays current alarms and actual values of the VSDs via web interface, including alarm history with a filtering option. Detailed logged trends also available for fast troubleshooting. The device currently used on a major conveyor system at client's production site.
CONTROL SYSTEM FOR PACKAGING TRANSFER TABLE
Develop a prototype of a control system for transferring table. Any prototyping project has hidden costs. Our goal was to asses the deadlines and budget requirements and only then proceed with the design and manufacturing. We have designed the control system, sourced the components and subcontracted the best electrical panel manufacturing company. The entire project has 32 electric motors which are controlled via FOX Controller. The control system has a switch for a few scenarios to achieve different package transferring patterns.
LOGGING OF WINCH TENSION
The requirement is to log winch tension during pulling electrical cable through underground cable channels and ducts. We utilised our Fox Controller to read oil pressure, display it in kN and log in a CSV file. When the CSV file is uploaded it's used for reporting to construction contractors.