The automated die punch system required a major control upgrade to improve reliability, usability, and integration with external systems. DMC was uniquely positioned to deliver this solution due to its expertise in Mitsubishi PLC programming, Ignition HMI development, and multi-system integration.
The client’s accelerated schedule required DMC to rapidly increase staffing to accommodate. DMC typically staffs a project of this size with three to five engineers. In this project, DMC scaled up to 11 engineers to hit the customer’s deadlines.
PLC and HMI Development
DMC reprogrammed the Mitsubishi PLC to handle all device functionality and automated sequences, including unwinder, punch, vacuum systems, and robotics. Communication protocols were implemented for vision, MES, and servo systems. On the HMI side, DMC developed an Ignition Edge application with screens for alarms, manual control, recipe management, OEE data, and traceability. Alarm and error handling were configured using the client’s error list, and CSV export functionality was added for trend data.
Robot Programming
DMC rewrote the existing Yamaha robot program to improve code readability and implement enhancements identified during a specifications phase. This included updating points and moves to optimize throughput and simplify onsite debugging.
System Integration
DMC architected a robust communication network linking PLC, HMI, vision systems, MES, and barcode scanners. Recipe handling and bypass settings were implemented to support flexible operation modes, including calibration and Gage R&R sequences for quality assurance.
Commissioning and Testing
DMC performed extensive offline development followed by onsite commissioning. Manual and automated sequences were validated, calibration routines tested, and communication with external systems verified. A user manual with annotated HMI screenshots was delivered to support ongoing operations.
By combining expertise across controls, HMIs, and robotics, DMC delivered a solution that enhanced reliability, significantly increased throughput, streamlined operations, and provided real-time operational insights.
Learn more about DMC’s Mitsubishi PLC and Ignition SCADA expertise and contact us for your next project.