Siemens S7 PLC Programming Case Studies

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DMC worked for a transportation company to upgrade their train car HVAC controllers from an outdated Simatic S5 platform to an S7-1200 PLC.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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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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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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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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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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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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