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High-Speed Motion Control for Aerospace with LabVIEW FPGA

Posted in Aerospace, LabVIEW Programming for Real-Time and FPGA, Manufacturing Automation and Intelligence, Motion Control Engineering and Servo Systems, Test and Measurement

DMC has worked closely with an Aerospace machine manufacturer to develop a high-speed control application for a highly coordinated process. Due to the nature of the process, an extremely complex and high-speed control strategy is required to ensure final product quality. The client recognized a proficiency gap in the processing technologies best suited to manage the controls application and reached out to DMC in order to supplement their development and design teams. DMC applied technology-specific...

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Quality Assurance Test Lab for Aerospace

Posted in Aerospace, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC's client runs tension and torsion tests for a series of parts that it manufactures. The company requires 100% inspection, which had formerly been conducted manually with significant operator involvement. The test stands utilized for inspection use an MTS 407 servo-hydraulic controller, and the customer wanted a fully automated system where a LabVIEW PC application could send commands to and control the MTS 407 controller. Previously, an obsolete MTS function generator was used to send a control...

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Large Scale Distributed Data Collection Using NI LabVIEW

Posted in LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC developed a server based test system designed to work with several common DAQ devices such as multipurpose Yokogawa and Agilent Acquisition Devices, and Yokogawa Power Meters. The customer needed a single test system that could be used across multiple laboratories or in a ‘stand alone’ instance for a single lab. The customer also wished to standardize the test system for use across multiple facilities in the U.S. and internationally.

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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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Rockwell RSLogix 5000 Add-on Instruction Programming for Herma 400c Labeler

Posted in Allen Bradley PLC Programming, Custom Software and Hardware Development, Manufacturing Automation and Intelligence, PLC Programming, SDK, API, and Driver Development

DMC created a fully functional Rockwell RSLogix 5000 add-on instruction suite for communicating with the Herma 400c labeling unit. The add-on instructions allowed for a modular communication method that controlled the labeler and read its status feedback, using both a set of digital IO and a more complex RS 485 configuration option. The client intended to integrate the labeler into several future machines, so the end result needed to be easily portable without any project-specific dependencies built...

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Pediatric Hospital Test Chamber with LabVIEW FPGA

Posted in Automated Test Stand Design, LabVIEW Programming, LabVIEW Programming for Real-Time and FPGA, Pharmaceutical & Medical, Test and Measurement, Test and Measurement Automation

DMC was approached by the Ann & Robert H. Lurie Children’s Hospital of Chicago to develop the world’s only Thermoregulatory Chamber designed and built from the ground up specifically for children. DMC worked with the hospital clinicians, researchers, architects, and construction crews to deliver this one-of-a-kind solution.

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High Speed Pharmaceutical Vision Inspection

Posted in LabVIEW Programming, LabVIEW Programming for Real-Time and FPGA, LabVIEW Vision Application Development, Manufacturing Automation and Intelligence, Motion Control Engineering and Servo Systems, Pharmaceutical & Medical, Test and Measurement Automation, Vision Inspection

DMC developed an eight-camera vision system to integrate with a pharmaceutical pill manufacturing system. The vision system used National Instruments’ Embedded Vision System and Basler Ace cameras to inspect each pill in order to verify that the pill was not cracked or damaged, preventing the delivery of an incorrect dosage to a patient through a cracked pill. 

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Automotive Sensor Testing and Programming

Posted in Automotive, Custom Software and Hardware Development, LabVIEW Programming, Manufacturing Automation and Intelligence, Test and Measurement, Test and Measurement Automation

DMC developed a new end-of-line test station for an automotive sensor manufacturing line. This system has shifted over the years from using a CAN Box system to using a system with TCP/IP communication. The new system tests and programs a wide range of different parts.

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Oven Temperature Monitoring with National Instruments Compact RIO and Microsoft SQL

Posted in Data Analysis, Data Mining, and Reporting, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC developed a temperature monitoring system designed to monitor and record approximately twenty industrial oven systems for the purpose of curing automotive sealant materials. Due to the nature of product development for these materials, it is critical that the curing process be precisely monitored for temperature fluctuation. The client found, experientially, that the most common failure mode of product samples was rooted in temperature fluctuations during the curing process. DMC was tasked with...

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DXF Import Application for 2D Wire Bending Machines

Posted in Custom Applications, Custom Software and Hardware Development, Manufacturing Automation and Intelligence, Product Development, Software and Web Development

DMC worked with AIM, Inc. to develop custom software for wire bending machines. AIM, Inc. developed the Smart Editor computer tool to simplify interfacing with the machinery. Their technology makes the transition from design to manufacturing quick and easy. DMC created a custom .NET application to import a DXF file with many parts into Smart Editor. This DXF Batch Importer modifies part geometry and automatically orients all the parts onto the XY-plane so that they can be manufactured with...

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Siemens SIMBA Profibus Simulation Engine

Posted in C# .NET Application Development, Custom Software and Hardware Development, Manufacturing Automation and Intelligence, PC Application Development, PLC Programming, Siemens S7 PLC Programming, Software and Web Development, Test and Measurement, Test and Measurement Automation

Using the Siemens SIMBA Profibus hardware interface, DMC created a software simulation engine for a client in order to support quick and efficient development of control software for high-tech materials manufacturing equipment. DMC’s low-impact solution reduced labor and test-time as well as increased up-time on the machines.

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Document Control in SharePoint 2013

Posted in Company Policy and Standard Operating Procedure Repository, Defense Contracting, Document Management, Enterprise Search, Microsoft Consulting Services, Pharmaceutical & Medical, Project Process and Project Management, SharePoint, Team Collaboration, Workflow

Essex Industries is a leading supplier to the Aerospace and Defense, First Response, Safety and Medical markets. DMC’s Consulting Services team implemented a Document Control Management System for Essex Industries using advanced features of the Microsoft SharePoint 2013 Enterprise Edition platform. The SharePoint Document Control Management System provides the Essex engineering teams with project collaboration sites that include a repository for new documents, document control with workflows...

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Low Power Consumption Product Design with the Texas Instruments MSP430

Posted in Circuit Design, Custom Software and Hardware Development, Embedded Development and Embedded Programming, Embedded Systems, Product Development, Texas Instruments Design

DMC worked with Chicago Dial Indicator (CDI), a leader in precision measurement devices to redesign their flagship electronic dial indicator. The previous platform was centered on an Application-Specific Integrated Circuit (ASIC) slated for obsolescence, necessitating a new part selection and design. The resulting low-powered system can handle high-speed data and includes connectivity to external devices over several interfaces, including USB Client, UART, Raw Signal Output, Mitutoyo Digimatic, and...

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High Speed Pharmaceutical Vision Inspection with NI Vision

Posted in LabVIEW Programming, LabVIEW Programming for Real-Time and FPGA, LabVIEW Vision Application Development, Manufacturing Automation and Intelligence, Pharmaceutical & Medical, Test and Measurement Automation, Vision Inspection

DMC developed a vision system to inspect a proprietary pharmaceutical product and the text printed on its packaging.  Due to the sensitive nature of distributing pharmaceuticals, DMC's client needed to ensure that 100% of their products were the proper size, had enough marking to identify the product, and that the product was accurately located in its package.  The client also needed to ensure that the text on the packaging was legible and accurate. DMC's solution needed to ensure...

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PLC-LabVIEW Industrial Communication

Posted in Allen Bradley PLC Programming, Consumer Goods, Data Analysis, Data Mining, and Reporting, Food and Beverage, LabVIEW Programming, LabVIEW Programming for Real-Time and FPGA, LabVIEW Vision Application Development, Manufacturing Automation and Intelligence, PLC Programming, Siemens S7 PLC Programming, Test and Measurement, Test and Measurement Automation, Vision Inspection

DMC has extensive experience connecting PLCs to LabVIEW on Windows and Real-Time targets. PLC-controlled assembly lines often require testing for quality. Many applications have the need to incorporate high-speed DAQ and complicated processing into end-of-line (EOL) testers. Because PLCs are ill-equipped to handle large arrays of data or run complex algorithms, it is common to augment a PLC-controlled operation with a more powerful and intelligent DAQ controller. This is also a great opportunity...

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