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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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High Speed Cutting with Fanuc Delta Robots

Posted in Beckhoff and TwinCAT 3 Programming, Food and Beverage, Manufacturing Automation and Intelligence, PLC Programming, Robotics

DMC worked with an established bread company to commission three Fanuc delta robots for automated bread scoring.

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Factory-wide MES Data Collection System

Posted in Business Intelligence, Custom Software and Hardware Development, Food and Beverage, Manufacturing Automation and Intelligence, Manufacturing Execution Systems, Microsoft Consulting Services, SQL Server BI

DMC implemented an extensive data collection system for a client in the confectionary industry. The resulting system allows the client a closer lens into their processes with automated data aggregation.  

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Integrating Kollmorgen AKD Drives with an Allen-Bradley PLC

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

DMC was hired by a machine builder who specializes in the frozen food industry to integrate six Kollmorgen AKD drives and servos with an existing PLC program. The Kollmorgen drives were chosen as a replacement for Allen-Bradley Ultra 3000 drives, which were no longer in production. The end result was an updated, robust program that can be easily modified for use on similar machines with any number of axes.

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Bread Factory Automation Using Beckhoff TwinCAT 3

Posted in Beckhoff and TwinCAT 3 Programming, Consumer Goods, Food and Beverage, HMI and SCADA Systems, Iconics Programming, Manufacturing Automation and Intelligence

DMC worked with an established bread company to commission a modernized, automated bread making system. The client had all OEM machines and controls equipment installed and ready for production but still required programming support to automate the system. The system contained numerous conveyors, cylinders, pan loading sections, and heaters. The end result was that the client could control and monitor the entire bread making system from a single HMI.

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Turnkey Solution for Food and Beverage Product Testing

Posted in Automated Test Stand Design, Business Intelligence, Data Analysis, Data Mining, and Reporting, Food and Beverage, LabVIEW Programming, Microsoft Consulting Services, SQL Server BI, Test and Measurement, Test and Measurement Automation

DMC designed and developed a custom test station and software for a beverage carbonator line to check for pressure leaks. The client needed a pressure decay test for a sub-assembly valve manifold in a restaurant-grade consumer appliance. DMC worked with the client to replicate and improve upon the manual test procedure, including interactive control and retesting ability. The product delivered was a complete, custom turn-key solution, involving mechanical, electrical and software engineering. Pressure...

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Basic Custom DAQ and Analyzer in LabVIEW

Posted in Custom Software and Hardware Development, Food and Beverage, LabVIEW Programming, Manufacturing Automation and Intelligence, Product Development, Test and Measurement, Test and Measurement Automation

In the process of designing a comprehensive End of Line (EOL) tester for a rapidly approaching product launch, DMC was asked to quickly design a very basic lab tester for the same UUT (Unit Under Test). DMC was ready to implement their custom software and ordered hardware within two days of the initial proposal. 

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Cognex and Siemens S7 Inspection System

Posted in Food and Beverage, Manufacturing Automation and Intelligence, PLC Programming, Siemens S7 PLC Programming

An existing packaging line had no inspection for glue quality. Bad glue lines were occurring every several days, resulting in machine downtime since an unnoticed issue would usually cause a jam. DMC utilized a Cognex Checker Vision Sensor to interface with a Siemens PLC in order to provide an inspection system. This solution utilized previous reject methods and decreased line downtime.

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PLC-LabVIEW Industrial Communication

Posted in Allen Bradley PLC Programming, Consumer Goods, Data Analysis, Data Mining, and Reporting, Food and Beverage, LabVIEW Programming, LabVIEW Programming for Real-Time and FPGA, LabVIEW Vision Application Development, Manufacturing Automation and Intelligence, PLC Programming, Siemens S7 PLC Programming, Test and Measurement, Test and Measurement Automation, Vision Inspection

DMC has extensive experience connecting PLCs to LabVIEW on Windows and Real-Time targets. PLC-controlled assembly lines often require testing for quality. Many applications have the need to incorporate high-speed DAQ and complicated processing into end-of-line (EOL) testers. Because PLCs are ill-equipped to handle large arrays of data or run complex algorithms, it is common to augment a PLC-controlled operation with a more powerful and intelligent DAQ controller. This is also a great opportunity...

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Automated Vibration Testing with LabVIEW

Posted in Food and Beverage, LabVIEW Programming, Test and Measurement Automation

DMC created a mobile vibration test apparatus to allow the customer to analyze their high speed manufacturing machines. By providing a flexible, easy to use system this solution allowed the customer to successfully benchmark the vibration, noise, and power consumption of their equipment.

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AB RSLogix to Siemens S7 Conversion

Posted in Food and Beverage, HMI and SCADA Systems, Manufacturing Automation and Intelligence, Motion Control Engineering and Servo Systems, PLC Programming, Siemens S7 PLC Programming, Siemens WinCC and WinCC Flexible Programming, Vision Inspection

DMC developed the PLC and HMI program for a high-throughput automated valve application machine. The machine stamped one-way air valves onto the packaging material in order to ensure coffee placed in the bag would remain fresh as long as possible. The system included interfaces to multiple outside systems including several smart camera vision check stations, a precision servo stamping mechanism, and another manufacturer’s downstream production lines

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Mitsubishi PLC Standard Library

Posted in C# .NET Application Development, Custom Software and Hardware Development, Energy and Utilities, Food and Beverage, Manufacturing Automation and Intelligence, Mitsubishi PLC and Automation Services, PC Application Development, PLC Programming, SDK, API, and Driver Development

DMC has long been a promoter of reusable code. With several of our PLC platforms, we generally have blocks for VFDs, valves, analog inputs, and many other common items that are regularly used in industrial situations. The benefit of these function blocks, is that once they are written and tested, a great deal of functionality can be achieved on future projects with very little effort. DMC's customer wanted a library of common blocks for Mitsubishi Q series PLCs. The solution...

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End of Line Test Station for Beverage Dispensing Valves

Posted in Automated Test Stand Design, Business Intelligence, Consumer Goods, Data Analysis, Data Mining, and Reporting, Food and Beverage, LabVIEW Programming, Microsoft Consulting Services, SQL Server BI, Test and Measurement, Test and Measurement Automation

DMC supplied a fully automated end-of-line tester for high-end beverage dispensing valves.  The system tests and calibrates each valve to ensure that it meets the client's stringent manufacturing standards.  The test stand supplies varying pressure water to the valve throught the test to simulate different real world conditions.  During each phase of the test, extremely accurate coriolis flowmeters within the test stand continuously monitor the flowrate through each section of the...

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