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Wireless Filtration Monitoring System

Posted in Custom Applications, Custom Software and Hardware Development, Embedded Development and Embedded Programming, Embedded Systems, Internet of Things (IoT), Microsoft Azure Cloud Solutions and Services, Microsoft Consulting Services

A client in the water treatment industry hired DMC to design a system allowing customers to manage water filtration systems across multiple locations. DMC developed a system to collect data from each filtration system and monitor their health both locally and remotely through the internet.

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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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Gas Compression System for Enhanced Oil Recovery

Posted in Allen Bradley PLC Programming, HMI and SCADA Systems, Manufacturing Automation and Intelligence, Oil and Gas, PLC Programming, Rockwell FactoryTalk

DMC worked with a leader in the gas compression industry to expand a custom gas compression system for enhanced oil recovery. The existing PLC program and I/O was extended to increase total capacity by bringing another compressor online.  

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Automated Fuel Pumping System

Posted in Energy and Utilities, HMI and SCADA Systems, Oil and Gas, Other PLC Platforms

DMC programmed a fuel management system that feeds generators to provide emergency back-up power to a mission critical 24-7 building. The end result was an automated fuel pumping system to keep the generators running as long as needed. 

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MES Recipe Management and SCADA Control System

Posted in Allen Bradley PLC Programming, Chemical, HMI and SCADA Systems, Manufacturing Automation and Intelligence, Manufacturing Execution Systems, PLC Programming, Wonderware Programming

DMC implemented a Wonderware SCADA and MES system for several chemical manufacturing lines. The system features a centralized recipe management system. The end result was a consistent product with reduced quality control issues.

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FactoryTalk Metrics OEE Reporting and Production Monitoring

Posted in Allen Bradley PLC Programming, Automotive, Business Intelligence, HMI and SCADA Systems, Manufacturing Automation and Intelligence, Manufacturing Execution Systems, Microsoft Consulting Services, PLC Programming, Rockwell FactoryTalk, SQL Server BI

DMC implemented a Rockwell FactoryTalk Metrics production monitoring and reporting system for an automotive supplier. FactoryTalk Metrics was configured to interface with the Allen-Bradley PLCs that control their production lines. DMC used SQL Server and SQL Server Reporting Services (SSRS) to customize data collections and reporting to fit the client challenges and needs. The end solution included real-time emailing of reports to key personnel.

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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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Sales Process Automation with Microsoft CRM and SharePoint

Posted in Business Intelligence, CRM Online, Custom Applications, Dashboards, Document Management, Microsoft Consulting Services, Office 365, SharePoint, Team Collaboration, Workflow

Stone Technologies, Inc. is a national Systems Integrator based in St. Louis, MO with offices in 16 states. Stone focuses on project delivery and provides manufacturing consulting and industrial automation services, including process control and manufacturing execution system (MES/MOM) design, software development, and commissioning. DMC’s Consulting Services team was asked to create a cloud / on-premises hybrid solution to automate the integration of Microsoft Dynamics CRM Online sales opportunity...

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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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Consumer Product Turnkey Appliance Test System with Power Measurements using LabVIEW

Posted in Automated Test Stand Design, Consumer Goods, Data Analysis, Data Mining, and Reporting, LabVIEW Programming, LabVIEW Programming for Real-Time and FPGA, Test and Measurement, Test and Measurement Automation

DMC developed a complete turnkey appliance test lab for a major manufacturer. The lab consisted of several custom-designed test-stands for conducting a variety of tests on ovens, cooktops, microwaves, clothes washers and dryers, dishwashers, and refrigerators. Several transducers were attached to the appliances and data was collected using custom software written by DMC. Both the hardware and software were designed to the customer’s specifications in order to facilitate comparisons to other...

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Simulator for Custom Gas Compression Equipment

Posted in Allen Bradley PLC Programming, HMI and SCADA Systems, Manufacturing Automation and Intelligence, Oil and Gas, PLC Programming, Rockwell FactoryTalk, Test and Measurement Automation

DMC completed an enhanced oil recovery project for a client in the oil and gas industry. Their machine, a large CO2 compressor, is used in the process of raising the level of oil in tertiary wells. DMC has enjoyed working with this client before on a number of projects aiding in code development, Factory Acceptance Test (FAT) test support, and commissioning in the field. DMC worked with the client to develop an Allen Bradley PLC-based compressor tester that simulates the numerous signals and different...

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NASA Battery Simulation System

Posted in Aerospace, Automated Test Stand Design, Battery Pack and BMS Test Systems, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC leveraged our established Battery Management System (BMS) Testing Platform to deliver an automated Battery Simulator System to a NASA research group. NASA needed this system to facilitate development of highly specialized battery devices. These battery systems were designed to provide mobile power for advanced electromechanical systems such as Robonaut 2, a dexterous humanoid robot created to perform a wide range of tasks to assist astronauts on the International Space Station. The Battery Simulator...

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Allen-Bradley to Mitsubishi Motion Control Conversion

Posted in Manufacturing Automation and Intelligence, Mitsubishi PLC and Automation Services, Specialty Machinery

DMC programmed a high precision six-axis honing machine for a Mitsubishi Q series PLC and QD77MS motion controller. The program was converted from an existing machine that used an Allen-Bradley CompactLogix PLC and Kinetix 6500 drives.

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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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EV/HEV Battery Pack Environmental Exerciser/Monitor System

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC designed, built, and programmed a set of automated test stands for charging and discharging electric vehicle battery packs. The test stands also monitor the performance of these battery packs while exposed to harsh environmental conditions for extended timeframes. To provide the necessary testing bandwidth and flexibility required by the customer, DMC's solution included five test stands designed to test a single battery pack, and two test stands designed to test up to six battery packs at...

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