Working with an OEM specializing in laboratory
autoclaves, we developed a detailed Software Design Specification (SDS)
from the existing PLC platform, improving functionality and adding
customer requested features. We then used the SDS to convert the system
to a different PLC brand. We still support this customer with
troubleshooting and improvements on both PLC platforms.
As part of a capital improvement project for a
major food manufacturer, we developed a program to use a series of
servo belts to meter stacked product into a packaging machine infeed.
The product was frozen and hand stacked upstream of the infeed system,
which was required to operate at speeds of up to 200 stacks per minute
with minimum gaps or upset stacks.
2D Vision Inspection
A company specializing in automated machinery
and contract manufacturing of metal parts required a vision inspection
station on a punch press being rebuilt for the manufacture of bullet
casings. The blanks were being inspected prior to entering the press in
order to reject outsized or misshapen blanks so that they would not
damage or jam the press. We were contracted to specify and supply a
vision inspection package including smart camera, lighting, programming
and startup services. To date, we have provided five identical systems.
|3D Vision Inspection System
We were contracted by a custom machine builder
to program a 3D machine vision system inspecting a pick-and-place head
for wear. The machine was part of a new line being installed for a
major chocolate manufacturer. The vision inspection was required to
meet food safety requirements, as wear on the pick-and-place head could
mean metal parts entering the food stream. The system included three
SICK IVC-3D cameras.
Flying Shear System
A major supplier of specialty metal alloys and
steels required an upgraded control system on two similar machines. The
machines turned coils of large gauge wire (1/2-1" in diameter) into
round or hex shaped bar stock by drawing them through a die and
straighteners, then shearing them into equal lengths. The first machine
used a decades old proprietary control system to control the wire draw
and flying shear functionality. The second system used a different
proprietary control system to control the flying shear. We were
contracted to help specify, program, and startup both systems. This
included analyzing the existing functionality of the proprietary
systems, programming and configuring the PLC-based motion system, and
replacing the existing user interface with touch panels. Both systems
were successfully started up, and the first system has seen a 50%
improvement in bar length tolerance.
|Thermal Oxidizer Control Panels
Working with a supplier of thermal oxidizer
systems, we have designed and manufactured PLC-based control panels
that interface with a variety of flame-safety devices and temperature
controllers to control a variety of high-output heating systems, from
waste incineration to the production of bio-coal.