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Manufacturing Automation and Intelligence

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Serial Communication with a Siemens S7-1200 PLC

Posted in Manufacturing Automation and Intelligence, PLC Programming, Printing, Siemens S7 PLC Programming

DMC programmed a Siemens S7-1200 PLC to communicate with servo controllers, using a serial interface. The serial communication was used to allow the operators to change the servo setpoints from a remote HMI.

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Automated Solvent Skid Control with a Schneider Electric Modicon PLC

Posted in Manufacturing Automation and Intelligence, Other PLC Platforms, PLC Programming

DMC worked with a client to develop a controls system for an automated solvent skid used to extract plant matter into concentrates. Through close coordination with the client, DMC set up, programmed and commissioned the first automatic prototype of the solvent skid. 

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Unitronics UniStream Controller for Pharmaceutical Application

Posted in HMI and SCADA Systems, Manufacturing Automation and Intelligence, Other PLC Platforms, Pharmaceutical & Medical, PLC Programming

DMC worked with a New England OEM in the pharmaceutical industry to upgrade an existing Unitronics Vision-series control system to a newer UniStream-series controller. DMC worked with the customer to implement new features that were not available on the previous controller. The Unistream controller also enabled the use of reusable functions and customizable modules to provide an organized solution that will be easier for the customer to maintain.

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PackML CPG Template State Machine Implementation for High-Speed Packaging Machine

Posted in Food and Beverage, Manufacturing Automation and Intelligence, Motion Control Engineering and Servo Systems, PLC Programming, Siemens S7 PLC Programming, Siemens SiMotion Programming

DMC used the PackML State Machine architecture to program a packaging machine for a food and beverage company. The machine coordinates the motion of several servo motors that together package a variable number of products at high speeds. This project was part of the customer’s larger initiative to revamp their packaging machines.

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Legacy Machine Retrofit with Siemens S7-1200 PLC

Posted in Inventory and Warehouse Control, Manufacturing Automation and Intelligence, Siemens S7 PLC Programming, Siemens WinCC and WinCC Flexible Programming

DMC worked with a Houston-based plastics processing company to perform a controls retrofit on a bagging machine which was outfitted with legacy control hardware that was no longer supported by the original manufacturer. The retrofit utilized Siemens S7-1200 PLCs and Comfort HMI.

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Intelligent Automotive Overhead Conveyor

Posted in Allen Bradley PLC Programming, Automotive, Manufacturing Automation and Intelligence, PLC Programming

DMC programmed a highly intelligent overhead conveyor solution for a leading automotive supplier. 

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Quickly Developing Prototypes with Siemens S7-1200 PLC

Posted in Consumer Goods, Manufacturing Automation and Intelligence, Motion Control Engineering and Servo Systems, PLC Programming, Product Development, Siemens S7 PLC Programming

DMC utilized a Siemens S7-1200 to program the controls for a prototype household appliance with two stepper drives. Typically, the application is geared toward embedded hardware. However, DMC utilized the low-cost PLC to implement a flexible solution to fit the client’s budget and schedule constraints. This made it possible for the client to invest less money to build a functional prototype which can be used to judge market demand.

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Cartesian Robot Control Using Siemens Function Block Library

Posted in Manufacturing Automation and Intelligence, Siemens S7 PLC Programming

DMC created and tested a library of Siemens function blocks for S7-300 PLCs using Simatic Manager that can be used to communicate with a  manufacturer's 6 axis Cartesian robot. The function blocks are now provided by the manufacturer so that end users can easily communicate with the robot and execute standard commands.

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High-Speed Bottling Machine with Siemens Servos and S7-1500 PLC

Posted in Manufacturing Automation and Intelligence, Motion Control Engineering and Servo Systems, PLC Programming, Siemens S7 PLC Programming, Siemens SiMotion Programming

DMC programmed a machine to fill small bottles of liquid at rates up to 1,000 bottles per minute, using several coordinated axes to transfer bottles between sections of the machine. Our role was to program and commission the motion aspects of the project, as well as to update existing code to use best practices with Siemens PLCs.

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Recipe Management and Execution with a Unitronics Samba PLC/HMI for Dual Kettle Brewing System

Posted in Food and Beverage, HMI and SCADA Systems, Manufacturing Automation and Intelligence, PLC Programming, Specialty Machinery

DMC created a Samba PLC/HMI program to create, edit, and perform brewing recipes for a Colorado-based manufacturer of small scale brewing equipment.

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12-Axis Honing Machine Using Siemens SIMOTION in Scout TIA

Posted in HMI and SCADA Systems, Manufacturing Automation and Intelligence, Motion Control Engineering and Servo Systems, Siemens SiMotion Programming

DMC created a standard architecture in Siemens' SIMOTION Scout that has been used on a dozen large and small honing machines. This project involved building a new machine based on that architecture and was used to control a three-station honing machine with a complete part handling system and an automatic gage system.

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Existing Plant Upgrade to Beckhoff TwinCAT 3 Using Standardized Reusable Code

Posted in Beckhoff and TwinCAT 3 Programming, Civil Infrastructure, HMI and SCADA Systems, Manufacturing Automation and Intelligence, Motion Control Engineering and Servo Systems, PLC Programming, Specialty Machinery

DMC worked with an established metal working company to modernize an existing automated custom metal-forming plant. DMC programmed new TwinCAT 3 PLCs with consistent code structure following best practices, which allows for easy feature additions to the system.

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FactoryTalk Data Historian Implementation with PLC and SCADA Programming

Posted in Allen Bradley PLC Programming, HMI and SCADA Systems, Manufacturing Automation and Intelligence, PLC Programming, Rockwell FactoryTalk

DMC developed a PLC program and corresponding SCADA system for the processing of krill oil. The system also utilized a historian to allow for long-term data storage and trending.

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Automated Oil Facility Data Collection with FactoryTalk Historian SE and VantagePoint

Posted in HMI and SCADA Systems, Manufacturing Automation and Intelligence, Oil and Gas, Rockwell FactoryTalk

DMC successfully installed and commissioned FactoryTalk Historian SE (Site Edition) and FactoryTalk VantagePoint at a crude oil facility that needed months of data collected. This upgrade also replaced the facility’s manual report entry with an automated system that could e-mail the reports to the supervisors.

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