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Factory Automation / Systems
Integration
What is a Systems
Integrator?
A Systems Integrator (SI) is someone that integrates
computer hardware and software, and mechanical equipment.
Thus the name "Integrator".
Experience
Tools we use:
- Programmable Logic Controllers - known as "PLC's" -
which are the industry bread and butter.
We have extensive experiece in programming Omron PLC's,
Allen Bradley PLC's, IDEC PLC's,
programming Opto 22 PAC controllers, programming
AutomationDirect PLC's, and large projects
using Beckhoff IEC 1131-3 open standard PLC's.
- Software for: Opto22, Omron, Allen-Bradley,
Automation Direct, IDEC, Beckhoff, Panasonic PLC's.
- We specialize in Moog Animatics Smart Motor Servo
motors - motor and electronics all-in-one
- Computers, Networks, Servers
- Bar code readers such as Keyence, and SICK
- Radio Frequency (RF) Tags and Tag readers
- Modbus communications
- All manner of I/O devices including devicenet
- Databases, data logging to disk, data trends,
etc.
We Service Older, Legacy
PLC's!
It can be very hard to find engineers who can service older
PLC equipment.
We keep older software and programming hardware around in
order to be able to service legacy PLC installations.
Some examples include Omron S6 and CXXK (C20K, C28K, etc),
SP16, C200H, CQM1, CPM1, & CPM2 PLC's and software,
Aromat / Matsushita / Panasonic FP-1 and M type controllers,
and older Opto 22 G4 and Mystic® controllers that use
the Cyrano or FactoryFloor® software. We of course have
the latest PLC software and hardware as well.
Industries
We have experience in a wide variety of settings -
aerospace, marine, food service, pharmaceutical, laboratory,
factory, enviromental remediation and cleanup, coffee
roasting, packaging and shipping, brewery control, autoclave
controls, hot bonders, automated aircraft radome testing,
gate control, security systems, etc.
We are experts in systems integration. You are an
expert in your process. We rely on you for knowing
your process, and can you rely on us for knowing the tricks
of the trade in automation systems design.
Sample integration
& automation projects:
Wet Lab
PID Control and Monitoring System
PROD
Seafloor Core Sampling Drill Unit
Programming
Coffee
Roaster Automation and Remote Roast
Reporting
Wet Lab Control and Monitoring
System:
The Client:
This client develops vaccines for
fish. The wet lab serves both as a fish hatchery, and as a
challenge area where the efficacy of a vaccine is proven
against a particular pathogen.
The Task:
Provide the client with design,
programming, and documentation for a monitoring and control
system.
System
Description:
The Control and monitoring system
controls such things as water temperature, oxygen
concentration, water filter flush routines, and chlorination
of effluent. In addition, extensive alarming with paging is
provided, as well as complete data logging. Monitored data
include temperature, flowrate, pressure, dissolved oxygen,
effluent chlorine concentration, differential pressure
across filter beds, PID control performance, etc. The
operator has full authority over all control and alarm
setpoints, including all PID tuning parameters.
Controller:
Opto22 G4LC32SX connected to two
HMI's (Human Machine Interface) via Arcnet. HMI's are
runtime app's created in the OptoDisplay component of
Factory Floor, and run under Win95.
Click below for more
info.
Challenge
row PID loop temperature control
Carbon
filter backflush control
Effluent
chlorination control
PROD Seafloor Core Sampling
Drill Unit Programming
The Client:
This client provides sea floor
mapping services using towed sonar arrays. They also have
participated in the design and construction of sea floor
core sampling drill units. This project involved the design
and construction of the latest such unit.
The Task:
Provide the client with automation
programming assistance.
System
Description:
Looking something like a mars
lander, the drill unit is lowered by cable to the see floor.
It is equipped with thrusters, lights and cameras for
manuevering. The operator sits on board ship and has remote
control of all functions of the drill unit. All motion is
hydraulic. The hydraulic power units and all I/O are
contained within cylindrical canisters mounted on the drill
unit. Power is routed down the cable. The controller directs
all of the drilling sequences which can be done manually or
automatically. Heading is maintained by a PID loop. Input
fault overides and sensor calibration are also available
from the HMI.
Controller:
Opto22 M4 controller connected to
an HMI (Human Machine Interface) via arcnet. The HMI is a
runtime app. created in the OptoDisplay component of Factory
Floor, and runs under Windows NT. Two monitors are
used.
Click below for more
info.
Drill
unit schematic
Landing
and leveling control screen
Utilities
screen
Coffee Roaster Automation and
Remote Roast Reporting
The Client:
This client provides specialty
coffees to the wholesale and retail markets. They
manufacture a coffee roaster that is available to customers
for roasting their product on-site.
The Task:
Provide the client with design,
automation and systems integration assistance. Create a PLC
program that runs the roaster, stores roast information, and
transmits it's roast history via automated dial-out to a
waiting MS Access appliction each day. Track inventory at
each store in the Access app. Documentation.
Training.
System
Description:
A gas fired roaster that roasts
beans in large batches. Operator selects bean recipe from
touch screen and follows prompts to complete each roast.
Scale weighs each batch to insure correct roast weight prior
to starting. Automated movement of beans from scale to
hopper and roast chamber.
Controller:
Omron C200HX controller connected
to a touchscreen operator interface.
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