Polyurethane Mixing Machine
Fifteen year old polyurethane mixing and pouring machine with obsolete control system
was completely retrofit with a new system based on a PLCDirect DL 450 programmable
controller. Material flow from three polymer tanks is precisely monitored by
precision flowmeters and controlled though Control Techniques vector drives. Process
temperatures are maintained by a glycol based heat transfer system controlled by the PLC.
Operator interface is accomplished through a PLCDirect DirectTouch panel. Supervisory
Control and Data Acquisition is maintained by a remote personal computer and Lookout Direct MMI
software through an ethernet connection.
Wonderware Parison Programmer Interface
Wonderware MMI software was used to create a custom operator interface for a Graham
Engineering Parison Programmer. The interface provides for eighty profile points to be
displayed and adjusted on one screen. Critical programmer parameters are password
protected with three levels of security. Up to four setups can be stored in the system,
but an unlimited number of setups can be stored and recalled from floppy discs. Setups
can also be opened in Microsoft Excel from which a graphical printout of parameters can be
Overhead Conveying System
An Allen-Bradley SLC-500 programmable controller supervises operation of a motor control
center with sixteen Allen-Bradley variable frequency A.C. drives. This equipment controls
an overhead conveyor system supplying two remote fully automatic palletizers with product
from three production lines. Elevators are used to raise the product overhead and to lower
the product back to palletizer level. The product wall is very thin requiring line pressure
controls to be built into the system at regular intervals. The PLC monitors fifty-eight
photo electric sensors to control twenty-seven gating devices which maintain even product
flow along the system. In addition to the electrical and pnuematic systems, all gating
devices were designed and installed by Applied Machine Control.
Die Cast Machining Center
Pneumatic and electrical controls were provided for this machine used to drill and tap
five holes simultaneously in end caps for pneumatic nailers. The part is automatically
clamped in a fixture where five Sugino drilling and tapping units finish the part. Motor
direction and speeds are controlled by Saftronics VSM variable frequency A.C. drives. The
entire operation is controlled through a Siemans Simatic S7 Programmable Controller.
MACO6000 Parison Programmer
A four head Uniloy blowmolder was retrofit with a Barber-Coleman MACO6000 parison
programmer. The system is set up to run individual parison profiles on each head as well
as function as a position based programmer. System logic and screens were modified to
allow the system to operate to the customer's specification. System math function was
utilized to automatically synchronize extruder shot parameters between two independent
parison programmer cards.
Eight Channel Parison Programmer
Plastic extrudate wall thickness is precisely controlled by hydraulically adjusting the
die gap dynamically during production. This PC based system provides closed loop
control to eight hydraulic servo valves, each controlling the die gap on an individual
extrusion head. Feedback is provided through LVDTs attached to the hydraulic
actuators. The operator interface, while extremely easy to use, allows the operator
to simultaneously run 100 point motion profiles independently on each channel. Two
separate CPUs are utilized, one for operator interface and one for motion control.
Data is shared by the CPUs using global RAM. The system operates at speeds up
to 300 cycles, or 2400 parts, per minute. Up to 100 user setups can be stored for
Inner Bearing Race Machining
This motion control application uses an Emerson FX Servo Drive and T60 Operator panel
to precisely control a finishing operation in the manufacture of roller bearings.
Motion parameters for each series bearing being manufactured are computed by the
system. The machine operator selects the bearing series number from a pick list on
the operator panel. Other machine control functions including parts handling are
accomplished using an Allen-Bradley SLC500 PLC.
Toxic Gas Alarm
Up to twelve analog electrochemical toxic gas sensors can be connected to this PLC
based alarm system. Alarm outputs include low level alarm, high level alarm, and
sensor failure for each channel. Adjustable parameters include gas type, engineering
units (ppm, ppb, %v/v, %LEL), alarm thresholds, alarm at concentrations above or below
threshold, and outputs high or low on alarm. Actual gas concentration is displayed
for each channel as will as fault conditions.
Automated Bulk Packaging System
Simple system utilizing PLCDirect PLC and Optimate panel to count product on conveyor
as it loads into a bulk box. Product flow is interrupted when preset count is
reached and full box is indexed out of system. New box is indexed into system and
cycle repeats. User can view count totals of products packed, boxes filled, and
products loaded to current box. System provides audible and visual alarms for
missing box and product jams.