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Allen-Bradley to Mitsubishi Motion Control Conversion

Posted in Allen Bradley PLC Programming, Manufacturing Automation and Intelligence, Mitsubishi PLC and Automation Services, PLC Programming, 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 Exerciser+Monitor System

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

The Battery Pack Exerciser+Monitor is an automated solution for functional and environmental battery testing, including evaluating charging and discharging performance of electric vehicle battery packs. In a production test environment, a focused functional check of a battery pack can be performed as it reaches the end of a production line. In an R&D environment, performance of a pack can be profiled while the pack is exposed to harsh environmental conditions for extended timeframes. To provide...

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Automotive Smart Sensor Testing in LabVIEW

Posted in Automotive, Data Analysis, Data Mining, and Reporting, LabVIEW Programming, LabVIEW Programming for Real-Time and FPGA, Test and Measurement, Test and Measurement Automation

DMC was approached by a large automotive corporation to aid in development of their NOx sensor test stand. The client’s staff developed the initial instrument drivers internally, but DMC was able to build a more formal architecture design and component integration. DMC worked closely alongside the client staff to produce a complete Real-Time and PC based test application.

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Turnkey Solution for Food and Beverage Product Testing

Posted in Automated Test Stand Design, Business Intelligence, Data Analysis, Data Mining, and Reporting, Food and Beverage, LabVIEW Programming, Microsoft Consulting Services, SQL Server BI, Test and Measurement, Test and Measurement Automation

DMC designed and developed a custom test station and software for a beverage carbonator line to check for pressure leaks. The client needed a pressure decay test for a sub-assembly valve manifold in a restaurant-grade consumer appliance. DMC worked with the client to replicate and improve upon the manual test procedure, including interactive control and retesting ability. The product delivered was a complete, custom turn-key solution, involving mechanical, electrical and software engineering. Pressure...

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Red Lion HMI Web Server to Read/Write PLC Tags

Posted in HMI and SCADA Systems, Manufacturing Automation and Intelligence, Mitsubishi PLC and Automation Services, PLC Programming, Specialty Machinery

DMC retrofitted a client’s existing PLC production system with a modern HMI. The Red Lion HMI provides a better user interface (UI) and is connected to the client mainframe, allowing recipe and job data to be easily loaded into the PLC from the server network. In streamlining their work-order process, DMC was able to increase the efficiency and competency of the client’s system.

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Structural Connector Loading System

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

DMC modernized the client’s existing test & measurement software to allow for additional lifespan, flexibility, and improved datalogging. This also included a complete interface remodel, giving the software a clean, professional, and functional look. The most important information is displayed prominently for the user, and previously inaccessible test history is now visible. The new DMC application builds on the older software’s architecture in order to preserve the familiar program...

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B&R Automation Tax Stamp Application

Posted in B&R Automation Studio Programming, HMI and SCADA Systems, Manufacturing Automation and Intelligence, Motion Control Engineering and Servo Systems, Printing

DMC's customer designs and manufactures machines that apply thermal transfer wax stamps to taxed products. In production, the machine opens, applies as many as 30 stamps, closes, and seals up to 90 products per minute. DMC troubleshot and modified the B&R programming so that the machines would run more reliably and require fewer stops.

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Basic Custom DAQ and Analyzer in LabVIEW

Posted in Custom Software and Hardware Development, Food and Beverage, LabVIEW Programming, Manufacturing Automation and Intelligence, Product Development, Test and Measurement, Test and Measurement Automation

In the process of designing a comprehensive End of Line (EOL) tester for a rapidly approaching product launch, DMC was asked to quickly design a very basic lab tester for the same UUT (Unit Under Test). DMC was ready to implement their custom software and ordered hardware within two days of the initial proposal. 

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LabVIEW Consulting and Training for Internal Development Team

Posted in Automotive, Data Analysis, Data Mining, and Reporting, LabVIEW Programming, LabVIEW Programming for Real-Time and FPGA, LabVIEW Vision Application Development, Manufacturing Automation and Intelligence, Test and Measurement, Test and Measurement Automation, Vision Inspection

DMC often provides consulting and training services to clients with internal development teams looking to enhance their design architecture. In this particular case, DMC was approached by an internal software team at a large automotive corporation to aid in the development of their smart CAN sensor test stand. The client’s staff developed the initial instrument drivers and brought in DMC for architecture design and component integration. DMC worked closely alongside the client staff to produce...

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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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