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Bed of Nails PCB Functional Test System, Automotive Gauge Cluster Controller

Posted in Automated Test Stand Design, Automotive, Embedded Systems, LabVIEW Programming, Product Development, Product Development, Test and Measurement

Printed Circuit Board (PCB) functional testing is a critical process in electronics manufacturing. Embedded PCB devices are becoming ubiquitous in products, provide intelligence to everything from basic consumer goods to complex industrial equipment. DMC delivered a turn-key, dual fixture (2-up) PCB Functional test system to help our client validate a new product. Backed by a National Instruments test stand, DMC applied LabVIEW test code and sequencing to automate the production testing...

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8-UP ECU Flashing Station

Posted in Automated Test Stand Design, Data Analysis, Data Mining, and Reporting, LabVIEW Programming, LabVIEW Vision Application Development, Test and Measurement, Test and Measurement Automation

Electronic Control Units (ECUs) are embedded modules that perform a wide range of essential functions within modern vehicles.  ECUs run firmware (embedded software) that gives ECUs their “intelligence” and governs their behavior and capabilities. The process of installing or updating this firmware on an ECU is commonly referred to as “flashing”. ECU Flashing is an essential process that transforms ECU hardware into a fully functional controller prior to being...

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Automated Tire Storage and Retrieval Control System

Posted in HMI and SCADA Systems, Manufacturing Automation and Intelligence, Manufacturing Execution Systems, Motion Control Engineering and Servo Systems, PLC Programming, Siemens S7 PLC Programming, Siemens SIMATIC PCS7 Programming Services, Siemens SiMotion Programming, Siemens WinCC and WinCC Flexible Programming, WinCC Open Architecture Development

Material handling systems are paramount to the tire and rubber manufacturing process. To ensure optimal production throughput, often a complex system of conveying, buffering, and storage units are deployed to the production floor. One critical material handling challenge applies to un-cured, green, tires. Tire building equipment often dramatically out-paces curing throughput capacity. Green tire inventory must be carefully managed to ensure uptime for tire builders, and steady output to the curing...

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Tire Conveying Control System

Posted in HMI and SCADA Systems, Manufacturing Automation and Intelligence, PLC Programming, Siemens S7 PLC Programming, Siemens SIMATIC PCS7 Programming Services, Siemens WinCC and WinCC Flexible Programming

As the tire and rubber industry incorporates more automated equipment on the product floor, product material handling systems are crucial to successful process automation. Production flow control and traceability can be a serious challenge for high volume manufacturers since each machine provides a highly specialized function. Often, the primary mode of transit for a tire in production are custom conveying systems. These systems solve a significant problem by eliminating manual handling of large products...

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Oil Well Control System Upgrade using an Allen-Bradley Control Logix PLC

Posted in Allen Bradley PLC Programming, Oil and Gas, Rockwell FactoryTalk

DMC worked with an oil and gas company to update and standardize their well pad control systems. DMC built a scalable program that can be configured by the client to fit each of their well pads of various sizes. This upgrade gives the customer the future flexibility to drill additional wells at a given asset, without requiring a major control system overhaul.

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PLC5 and Wonderware to SIMATIC ET200 CPU and LabVIEW Upgrade for HVAC Test Chamber

Posted in Allen Bradley PLC Programming, Automotive, HMI and SCADA Systems, LabVIEW Programming, Manufacturing Automation and Intelligence, PLC Programming, Siemens S7 PLC Programming, Siemens SIMATIC PCS7 Programming Services, Test and Measurement Automation, Wonderware Programming

DMC worked with an automotive manufacturer to upgrade their HVAC test chamber controls from an outdated system that utilized an Allen Bradley PLC5 PLC with a Wonderware HMI. DMC's solution converted the test sequence controls and user interface to a LabVIEW application and the device controls to a SIMATIC ET200 CPU to align with other test chambers in their facility.  This project was a great opportunity for DMCers all around to work together as we collaborated across our Manufacturing...

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The DMC Multi-Protocol CAN Logger

Posted in Data Analysis, Data Mining, and Reporting, J1939 LabVIEW Drivers, LabVIEW Programming, TDMS File Viewer, Test and Measurement, Test and Measurement Automation

DMC has many clients who require simultaneous logging of all CAN traffic on a number independent of interfaces, so we designed a Multi-Protocol CAN Logger (MPCL) that can operate stand-alone or integrate with existing systems.

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Control System Consolidation and Upgrade

Posted in Allen Bradley PLC Programming, Civil Infrastructure, Energy and Utilities, HMI and SCADA Systems, Manufacturing Automation and Intelligence, Oil and Gas, PLC Programming, Siemens S7 PLC Programming, Siemens WinCC and WinCC Flexible Programming

DMC modernized and consolidated a control system used to purify water for a dual cycle, gas turbine power plant. Three separate control systems utilizing a diverse set of hardware and software were all combined into a single TIA Portal V15 Project. DMC provided a turnkey solution, handling the hardware purchase and install in addition to software. We worked with the client about nine years ago to make different additions and upgrades to the original system. The switchover from the old system to the...

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Assembly Line Andon and FactoryTalk Metrics System

Posted in Custom Software and Hardware Development, HMI and SCADA Systems, Manufacturing Automation and Intelligence, Manufacturing Execution Systems, Other PLC Platforms, PLC Programming, Rockwell FactoryTalk, Web Application Development

DMC implemented a performance tracking and data collection solution for a client in the manufacturing industry to summarize overall line performance and analyze production targets. After we rolled out the initial solution, the client came back to us for an additional functionality through a second phase of work.

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Batch Control Upgrade with Siemens PM-Control

Posted in Custom Software and Hardware Development, Food and Beverage, HMI and SCADA Systems, Manufacturing Automation and Intelligence, SDK, API, and Driver Development, Siemens WinCC and WinCC Flexible Programming, User Interface Design

DMC worked with a trusted, partner integrator, AIC, and Siemens, to upgrade a supervisory batch mixing system by utilizing Premium WinCC add-ons and a custom front-end interface. The previous system was a Wonderware/In-Batch driven solution running on aging computing equipment that put the business resumptions at significant risks.

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Brewing Template and Founders Brewing Implementation

Posted in Food and Beverage, HMI and SCADA Systems, Manufacturing Automation and Intelligence, PLC Programming, Siemens PROFINET, Siemens S7 PLC Programming, Siemens WinCC and WinCC Flexible Programming

DMC worked with Siemens to develop a robust and modular brewing template project geared towards craft brewers. To decrease future development time, DMC developed tools using Openness and SiVarc to quickly create and link control modules on a PLC and HMI. DMC implemented this solution, including custom additions, for Founders Brewing, one of the most prominent craft breweries in Michigan, in their new Detroit brewpub. 

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Bluetooth Add-on and Windows Application for Measurement Automation

Posted in Circuit Design, Custom Software and Hardware Development, Embedded Development and Embedded Programming, PC Application Development, Product Development

DMC developed a Bluetooth add-on for industrial measurement gauges with Digimatic interfaces to add wireless connectivity for transmitting measurements. DMC also created an accompanying Windows application that runs on a tablet to receive, interpret, and record the data.

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Flexible Automated Test System with DMCquencer

Posted in Custom Software and Hardware Development, LabVIEW Programming, Test and Measurement Automation, Web Application Development

DMC developed a flexible automated test suite for performing electrical tests on a variety of data logging devices and sensors. The software was based on DMC’s reusable test framework called the “DMCquencer,” which allows the client’s engineers to configure their own test sequences without requiring programming knowledge. A SQL database logs the test results. The results are then reviewed in a custom web application developed in ASP.NET Core. The web application also provides...

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