Case Studies

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Package Room Access Control System Hardware & Firmware Programming

Posted in Application Development, Circuit Design, Consumer Goods, Embedded Development & Programming, Microchip Design, Web Application Development

DMC designed a custom printed circuit board to control access to a secure package room and act as a backup power supply for a kiosk PC. DMC also implemented firmware for supervising the backup power supply and door control. 

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Configurable Locker System Firmware Development

Posted in Application Development, Circuit Design, Consumer Goods, Embedded Development & Programming, Embedded Systems, Product Development, Web Application Development

The client first came to DMC for a review of the embedded design for a PCB and complete firmware programming of an automated locker system for packages. Since then, DMC has made multiple updates to the system with the most recent update being programming the system to be more modular and configurable.

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Cloud-based Web Application for Self-Guided Apartment Tours

Posted in Application Development, Internet of Things (IoT), PC Application Development, Web Application Development

DMC developed a cloud-based solution to enable prospective residents to tour apartment complexes unattended. Prospects sign up for a tour at participating properties by visiting a public facing sign-up form, where they can enter their contact information and complete a credit card verification and/or ID verification depending on the requirements of the property. Before their tour, prospects receive entry instructions via email and/or text and download a customized tour app, which provides guidance...

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Control System Upgrade to NJ101 PLC With Direct SQL Data Recording

Posted in Automotive, Manufacturing Automation and Intelligence, PLC Programming

DMC upgraded a controls system from an all-in-one PLC/HMI to a dedicated Omron PLC with built-in SQL communications for a customer in the automotive industry.    

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Simatic S7 Upgrade for High Temperature Flammable Gas

Posted in HMI and SCADA, Manufacturing Automation and Intelligence, PLC Programming, Semiconductor, Siemens PLC, Specialty Machinery

DMC upgraded an existing high temperature, high vacuum, hydrogen furnace system that used a Microbox Panel PC running WinAC RTX and several PC applications. The customer reached out to DMC for a single technology system, that would be easy for their own engineers to maintain and modify for future systems. The solution upgraded the Simatic Manager Software Controller to the TIA Portal Failsafe Software Controller with WinCC RT Advanced and reused the existing hardware.

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Lithium-Ion Battery End-of-Line Test Stand Development

Posted in Automotive, Battery Pack Test Systems, Energy and Utilities, Green Technology, LabVIEW, Manufacturing Automation and Intelligence, MES, Test & Measurement Automation, Test and Measurement, Test Stand

DMC delivered an automated production test station to an international manufacturer of large, commercial, rechargeable lithium-ion batteries. The system performs essential end-of-line functional verification of both battery packs and battery modules. The client provided DMC a high-level test specification, and from this, we were able to rapidly deliver two complete test systems configured to the client’s needs. We achieved this within the client’s fast-moving timeframe driven by start-of-production....

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LabVIEW UI Customization with Grid Viewer

Posted in LabVIEW, Test & Measurement Automation

The DMC Grid Viewer is a stand-alone part of the Flex Framework which allows users to create a dynamic user interface using a drag-and-drop method. The LabVIEW UI customization offered by the DMC Grid Viewer is a key facet for building a flexible application using the Flex Framework.  

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Streamline Hardware Configuration with the Hardware Abstraction Layer

Posted in LabVIEW, Test & Measurement Automation

The Hardware Abstraction Layer is a powerful part of the Device-Module hierarchy present in DMC's Flex Framework. It allows developers to easily integrate new pieces of hardware, and users to switch between hardware configurations on-the-fly.

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Adding User Authentication to Your LabVIEW Project

Posted in LabVIEW, Test & Measurement Automation, Test and Measurement

Most industrial applications require user access levels to protect sensitive information, protect equipment, or to log specific events with the current user. These access levels hold true for test and measurement applications as well. For this reason, DMC developed a set of independent VI’s that can be integrated into any project to add user access levels. The different levels can then be utilized to control the program’s available functionality based on the user logged in.

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Customizable UI in DMC's Flex Framework

Posted in LabVIEW, Test & Measurement Automation, Test and Measurement

DMC’s Flex Framework is a powerful tool that improves our development time for complex projects, and it provides our clients with access to an abundance of functional code modules. Projects have the potential to utilize our DMCquencer logic, User Access Level logic, module grid viewer, and many other code modules. One pitfall for large and complex project frameworks is that they come with a predesigned and constrained User Interface (UI) that the new project must also adopt. The result is an...

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Flexible Logging with the LabVIEW Results Manager

Posted in LabVIEW, Test & Measurement Automation, Test and Measurement

The LabVIEW Results Manager is a highly flexible logging module that can easily create, grade, and log test measurements and save them to locations ranging from a web database to CSV text files.

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Custom Alarm Handling Toolkit for LabVIEW

It's easy for users to feel helpless when errors or warnings occur in a system that they do not understand. The default LabVIEW error wire information can be cryptic to users who aren't familiar with the guts of the program. Creating a robust alarm handling framework from scratch to appropriately display and respond to errors and warnings can be challenging and time-consuming. DMC developed the Alarm Handling Toolkit to help track, respond to, log, and display any errors, faults, warnings,...

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Automatic and Manual Automation Modes in DMC’s Flex Framework

Posted in LabVIEW, Test & Measurement Automation

As an engineering consulting company, DMC often works with clients to automate their manufacturing or testing processes. One frequent challenge is how to provide diagnostic tools and capabilities for engineers while providing a simple, one-click testing solution for operators on the same test station. DMC’s Test and Measurement team has a common toolchain called the Flex Framework. A group of automation modes (namely a ‘"Manual" Mode and an "Automated" Mode)...

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Efficient Configuration Management with Flex Framework

Posted in LabVIEW, Test & Measurement Automation

A common challenge tackled by test systems is effective configuration management. Consider even a simple power supply. There may be configurations to ensure that the device is talking at the right Baud rate over the correct communications port. There are communication protocol configurations to ensure that the right messages are being sent for this model of power supply. There are also test configurations to ensure that the power supply ramps up and down to the required voltage...

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Function Block Diagram Programming for Plasma Treater

Posted in Food and Beverage, HMI and SCADA, Manufacturing Automation and Intelligence, Packaging Machinery Programming, PLC Programming, Printing, Siemens PLC

DMC utilized Function Block Diagram (FBD) logic to write both operational and safety logic for a plasma treater used in the label printing process of cardboard beverage containers. FBD is a style of PLC programming that has a different graphical interface from the more commonly-used ladder logic. The differences between these two programming styles will be addressed later in the case study. 

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