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Siemens S7 PLC Programming

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IoT Waste Management with Siemens PLCs and Microsoft Azure

Posted in C# .NET Application Development, Custom Software and Hardware Development, Manufacturing Automation and Intelligence, Microsoft Azure Cloud Solutions and Services, Microsoft Consulting Services, PLC Programming, Siemens S7 PLC Programming, Web Application Development

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

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Trash compactor
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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Siemens ET 200SP CPU
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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Siemens CB 1241 RS485 Serial Adapter
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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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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Pack-ML-Siemens-PLC
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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plastic-pellets
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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Photo of Siemens Simatic S7-1200 PLC.
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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3D model of Cartesian robot
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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Siemens S7-1500 PLC
PLC Programming and SCADA System for Pilot-Scale Coal Burning Power Plant

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

DMC developed the PLC program for a pilot scale coal burning power plant, as well as a SCADA system using Siemens WinCC 7.2. The SCADA system included an HMI designed with the end user in mind, as well as custom logging scripting.

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Smoke stacks at a coal-burning power plant
Safety-Rated Wireless Control for High-Tech Retail Using Siemens IWLAN and SCALANCE W Hardware

Posted in Building Technology, Manufacturing Automation and Intelligence, PLC Programming, Siemens S7 PLC Programming

DMC programmed and commissioned a Siemens Wireless Safety system to safely operate and monitor two-story tall glass doors for a Silicon Valley, CA-based technology company's flagship retail electronics store.

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Siemens-IWLAN-and-SCALANCE
Hose and Cable Reel Management Control System for Offshore Drilling

Posted in HMI and SCADA Systems, Manufacturing Automation and Intelligence, Oil and Gas, PLC Programming, Siemens S7 PLC Programming

DMC programmed a Siemens-based cable and hose reel management control system for use in offshore drilling for a Houston, TX based Oil and Gas OEM.

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Simatic S5 Revival and Conversion to S7

Posted in Civil Infrastructure, Manufacturing Automation and Intelligence, PLC Programming, Siemens S7 PLC Programming

DMC was hired by a transportation company to revive six malfunctioning S5-100U PLCs that are used to control HVAC systems. 

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Expandable Process Control System with WinCC OA

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

DMC was hired by a company in the medical devices field who was creating a new fluid process mixing and bottling line. DMC created an expandable process control system with CFR 21 Part 11 compliant audit trail capability.

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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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