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Function Block Diagram Programming for Plasma Treater

Posted in Food and Beverage, HMI and SCADA Systems, Manufacturing Automation and Intelligence, Packaging Machinery Programming, PLC Programming, Printing, Siemens S7 PLC Programming

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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Siemens Programming, Commissioning, Plant Start-Up, & Support for Paper & Pulp Processing Plant

Posted in HMI and SCADA Systems, Manufacturing Automation and Intelligence, PLC Programming, Siemens S7 PLC Programming, WinCC Open Architecture Development

DMC provided Siemens PLC and Siemens WinCC OA programming for a pulp processing plant in the paper and pulp processing industry. This included offline programming, commissioning, plant start-up, and ongoing support.

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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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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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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 utilizing OEE, Downtime Monitoring, and Track & Trace functionality 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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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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Simatic S5 to S7 Upgrade for Train HVAC System

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

DMC worked for a transportation company to upgrade their train car HVAC controllers from an outdated Simatic S5 platform to an S7-1200 PLC. DMC’s solution included new features such as an HMI panel, data logging, and flexible implementation ability.

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Legacy System Upgrade with Siemens TIA Portal and WinCC Advanced

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

DMC worked with a biological research firm to upgrade a highly customized legacy SCADA application and a Think & Do PC-based controller to WinCC Advanced combined with a space-saving ET 200SP PLC. DMC replicated existing functionality while expanding operator usability and data manipulation options through customized WinCC Advanced interaction.

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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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Keyence Camera Integration with a Siemens S7-300 PLC

Posted in Food and Beverage, PLC Programming, Siemens S7 PLC Programming, Vision Inspection

DMC worked with a confectionery company to retrofit a high-speed packaging machine with a Keyence camera vision system. The camera detects bad, incomplete, or missing product and triggers an S7-300 PLC system to reject the product prior to packaging.  

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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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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. This particular solution was designed for THC extraction from cannabis plants, but can be used for any type of plant. Through close coordination with the client, DMC set up, programmed and commissioned the first automatic prototype of the solvent skid. 

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