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. 

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.

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...

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...

DMC worked with an automotive manufacturer to upgrade their HVAC test chamber controls from an outdated system that utilized an Allen Bradley PLC5 PLC with a Wonderware HMI.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...

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...

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. 

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.

DMC developed an Azure-based IoT waste management solution for monitoring trash compactor fullness.

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.

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.

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.  

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.

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.

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.