We wrote code to deliver inputs and read outputs from the customer code and communicate with higher-level building automation systems. The PLC development included debouncing digital signals and scaling analog signals. We designed the PLC interface with fan controllers over Modbus/RTU as well as send commands from the customer code to physical outputs. We implemented fieldbuses to allow for end customer control of the units over Modbus/RTU, Modbus TCP/IP, Profinet, BACnet IP, and BACnet MS/TP. Field bus parameters can be modified directly on the HMI. 

We also developed HMIs to view the cooler status. Our solution allows end customers to modify fieldbus parameters quickly without having to open the Beckhoff programming environment. Historical and alarm data are logged to internal memory, and end customers can export that data to an external drive.  

DMC worked with the client to develop a procedure for deploying to new machines in their production facility that did not require the use of any specialized programming software. Our solution was a combination of the Beckhoff Service Tool and custom code on the IPC to apply settings. The solution allows users to import a configuration file that can adjust the PLC program to the correct hardware and software settings. 

Learn more about DMC’s Beckhoff programming expertise and contact us for your next project. 

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Data Collection, Standardization, and Organization 

The system uses AUTOSOL ACM to connect to thousands of distributed field devices using protocols like Modbus, ABB Totalflow, and Allen-Bradley Ethernet IP. ACM then hosts the tags for Ignition to read over OPC-UA. Ignition uses UDTs and a strict tag hierarchy to maintain standardization between different equipment of the same type. 

Ignition collects data, stores trends in the tag historian, and displays tag data on dynamic screens. Navigation and displays are driven by database tables to automatically update when new sites are added. Screens use high-performance HMI design to give operators at-a-glance equipment health and performance information. 

Automated Equipment Rollout Process 

DMC designed the system to automatically generate all required equipment configuration from a template spreadsheet file. This creates AUTOSOL import files and Ignition tags, so users do not have to manually add equipment to the system. The auto-generation process is designed to both create new equipment and update existing equipment, making it easy to roll out changes to the field.  

Data Reporting and Integrations 

DMC developed custom dashboards and reports to display critical production information. Reports contain a mix of user-submitted information, trend aggregations, and live data. Reports and data can be accessed via several different means: 

• Ignition dashboard screens 
• Export-to-CSV downloads 
• REST API data endpoints 
• Alarm text, email, and phone callouts 

Conclusion 

With their new Ignition/AUTOSOL SCADA system, the client has much greater visibility into their field-wide data. They can build on DMC’s modular architecture to quickly roll out new sites and develop new features.  

Learn more about DMC’s Ignition SCADA Programming expertise and contact us for your next project.

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The result? A tailored, high-performance solution delivered with exceptional speed, minimal disruption, and long-term adaptability. The client was thrilled with the turnaround time, functionality, and overall value.

Learn more about DMC’s LabVIEW programming services and contact us for your next project.

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Historically, this data collection was performed manually, with a single individual responsible for daily measurements. This approach left nights, weekends, and holidays often unmonitored or required continuous lab staffing. As a result, experiments were frequently compromised by deviations in temperature or material flow that occurred during these unmonitored periods, making it necessary to restart experiments, resulting in wasted time, materials, and personnel resources.

DMC delivered a custom hardware solution that integrated existing scales, pumps, and sensors into a PLC-based control system. By leveraging serial servers to connect over 100 devices, DMC avoided the need for dedicated point-to-point connections. This approach combined legacy technology with modern infrastructure, resulting in a solution that was delivered on budget, significantly reduced the size and cost of the electrical panel, and greatly simplified field wiring, improving both installation efficiency and long-term maintainability.

DMC’s solution integrated an intuitive SCADA system, serial servers, and a PLC to provide comprehensive test automation and monitoring capabilities. The entire team can now review experiment data, both remotely and onsite, with all data stored securely in databases to enable efficient reporting and analysis.

If temperature or flow conditions begin to drift outside of acceptable ranges, the system automatically issues email alerts, allowing timely intervention before minor deviations escalate into major setbacks.

This automation has eliminated the need for late-night manual data collection, reduced the risk of transcription errors from handwritten records, and removed the uncertainty of unmonitored weekends. With DMC’s lab automation in place, our client can focus on further research and innovation rather than routine operational tasks.

Learn more about our Manufacturing Automation and Intelligence expertise and contact us for your next project.

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A series of automated tests is performed on each frozen beverage machine, and data is collected and stored in a centralized database.  For each test step, the system sends commands to the product’s CPU through digital communication.  The product’s response to the command is measured and recorded using pressure, temperature, voltage, and current sensors.  Each result is compared to allowable test limits, and a pass/fail determination is made.  Upon test completion, a full report is automatically generated and sent to a network printer.  A web-based reporting system allows supervisors to immediately view test status and results remotely and respond quickly to problems.  Historical data is logged, providing a key tool for ongoing process improvements.

Learn more about our Test & Automation Solutions for Food and Beverage and contact us today for your next project.

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Our engineers created a control architecture with a standard hardware set. We utilized a standard library of process objects for PLC software and HMI controls. To allow operators to safely de-energize any piece of equipment from any of 11 remote control stations, DMC also designed a network of safety PLCs and other SIL 3 components.

Our team designed 30+ control panels to meet the UL508A standard. To meet hazardous location requirements, we utilized a combination of explosion-proof and intrinsically safe components. Collectively, we focused on the complete software development lifecycle, from requirements gathering to detailed design and programming, as well as the development and execution of test plans.

Finally, we coordinated with the construction team for power and telecommunication infrastructure.

Learn more about DMC’s PLC Programming Expertise and contact us for your next project.

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DMC later revisited the client’s facility to develop architecture for their confectionary equipment and implement it in a second confectionary facility. It was an improvement on the custom equipment code. This allowed the client to expand to another refining line at the second facility with the custom control system DMC developed.

Most recently, DMC was involved with developing a third facility for the client based on the existing background technology DMC had developed previously for the first two facilities. DMC used the existing architecture and applied it to the client’s specific configuration of refining lines and ingredient systems. This was beneficial for the client because the cost of development for a new refining line was lower compared to rebuilding the technology from the ground up. DMC frequently traveled onsite to assist with the startup of the facility and continued to add new features and new flexible options, allowing the client to make changes on their own.

When the third facility experienced an IT issue that caused limitations on receiving diagnostics, DMC wrote a C# application to collect the recipe information integrating with the SQL database to obtain recipe information that provides better diagnostics.

DMC’s expertise in WinCC Professional and SQL database qualified us to provide a modern upgraded solution and successfully reuse and update existing background technology for the third confectionary equipment facility.

DMC’s work on the client’s three confectionery equipment facilities allowed the client to expand and add new tanks, add new ingredients, reduce the cost of refining lines, and utilize a more flexible code base.

Learn more about our Manufacturing Automation and Intelligence expertise and contact us for your next project.

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DMC first audited and updated the plant’s interlock. During this process, DMC found several interlocks needed to be bypassed for normal operations and the majority did not serve adequate safety or protection purposes. DMC leveraged the built-in functionality of the PCS7 APL Interlock objects to link devices together so that operators could click on and navigate through the whole interlock matrix to see what was stopping them and why they were interlocked. This added clarity, reliability, safety, and insight into the system, so that the client could now run manually, if needed. 

Once the batch rewrite in PCS7 was complete, DMC implemented a historian and batch reporting system in Ignition to provide better visibility into the plant’s processes. We used OPC UA to pull data via the PCS7 WinCC 7 HMI using the PCS7 Connectivity Pack. 

After experiencing the capabilities of Ignition, the client decided to add additional features beyond data collection and reporting. One of the client’s goals was to streamline their data and document handling surrounding material shipping and receiving, which was previously managed through multiple manually maintained spreadsheets. DMC developed a custom integration to the client’s LIMS systems to compile batch quality test data from multiple sources into a single database. DMC then developed integrations to PCS7 and the client’s truck loadout system to automatically track and release batches for loadout and generate BOLs incorporating the batch quality data. In the end, the entire loadout process could be carried out on a tablet, including operator interfaces for loadout inspection and signoff signatures. 

Learn more about DMC’s Manufacturing Automation and Intelligence expertise and contact us today for your next project. 

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• Communication and control interface between SAP and the line equipment. 
  • Collected data from the equipment and sent it to SAP. 
  • Retrieved recipe information from SAP and sent it to the equipment. 
  • Interfaced with the line equipment which included a mix of devices such as PLCs, torque tools, custom applications, etc. 
• High fidelity data collection that resulted in of a large amount of data per battery module
• High resolution image collection from multiple vision inspection systems

Figure 1-weld review. Shows a high-level view of which cells in the module have failed. Allows the user to click on a cell to get more information. 

DMC joined the project during the design phase to advise on the overall architecture between the SAP and controls layers. SAP PEO was a novel platform without a standard method to talk to machine devices, so the client sought a partner with experience integrating complex systems. DMC worked with the client on designing the system and developing functional specifications which included defining the specific message structures for passing data between all systems. 

Once the specifications were complete, DMC developed the code offline. Getting an early start on development offline enabled us to meet a tight deadline. As a part of the project process, we held weekly check-ins with the client to review the project status and demonstrate the software via simulation to keep a tight feedback loop on development. DMC also worked closely with the SAP development team to ensure the two systems would communicate seamlessly once deployed. This included multiple rounds of UATs, weekly check-in meetings, and quality checks. 

When offline development was complete, DMC went onsite to the customer’s facility to successfully commission the system and perform operator training. DMC’s flexible code structure and robust logging systems made it easy to test the live system and make last-minute changes, resulting in an on-time SCADA acceptance test.  

Figure 2-line overview. Shows the status of each station in the line.

Figure 3-transaction log. Shows a detailed summary of the communication between SAP and the PLCs.

Learn more about DMC’s Ignition programming expertise and contact us with any inquires.

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The client chose DMC to help automate a complex assembly machine with a fast-approaching project deadline. DMC handled the full software implementation including PLC development, HMI screens, robot programming, motion control, and commissioning. 

The system consisted of two PLCs: one that controlled the assembly portion of the process and one that controlled the packaging. 

Assembly Machine: 

• SuperTrak conveyance connecting 11 stations
• Assembly of input components by drives and pneumatic actuators
• Denso robot part handling
• Operator HMI for system monitoring and manual operations

Packager Machine: 

• Denso robot part handling
• Servo motor-controlled tray handling
• Interface with assembly machine
• Operator HMI for system monitoring and manual operations

Each machine had its own PLC program that was created using Rockwell’s Logix Designer programming environment. To coordinate part handoff between machines, the two PLCs communicated to each other through produce/consume tags.  

Assembly and Packaging Machine HMIs

DMC programmed HMIs for the assembly and packaging machines using FactoryTalk View SE. Each HMI displayed common information about the state of the system, information specific to assembly or packaging processes, and dynamic graphics to show the status of devices interfaced with the PLC. System warnings and faults detected in the PLC and robot code were displayed on the HMIs using descriptive alarms, which decreased the need for monitoring of the system. 

Standard Architecture

DMC began work by creating a standard architecture to be used by both machines. The architecture was structured around Pack ML (ISA-TR88). This predefined structure helped ensure that the machines could properly transition from a stopped state to a running state in an organized manner. The consistency provided with Pack ML also helped ensure that the two machines were properly coordinating their operations together. 

A safety program was created to minimize any risk to machine operators. All system motion could be stopped by any one of the E-stops on the machine or if any of the doors of the system were open during machine operation. To allow maintenance staff to accurately diagnose any issues that might come up on the machine, DMC programmed controls allowing some limited system motion when the machine’s doors were open. This feature could be activated by turning a safety rated bypass key switch. 

SuperTrak Conveyance System

Much of the Assembly Machine’s operation centered around its SuperTrak Conveyance system. For this project DMC utilized SuperTrak’s TrakMaster software to configure the track behavior and created PLC code to integrate the track with the rest of the system. In order to meet the aggressive performance target from the client, DMC had to finely tune the SuperTrak system to minimize part transit time and reduce track overheating. 

Parts were loaded onto the track using three Denso robots. DMC programmed these robots to pick incoming parts up and move to the track in an optimized path to maximize the throughput of the line.  

Keyence vision systems were used to inspect parts at several points in the assembly process to verify that the parts were acceptable. Any faulty parts would be unloaded into a bin for analysis. 

Once parts were fully assembled, a fourth Denso robot would use a vacuum gripper to pick it up from the track and move it to the packager machine. There, the packager would organize the parts into trays and then stack those trays together once they were full. The stacks were then moved onto a conveyor, which made for easy and efficient operator unloading. 

DMC’s experience allowed us to successfully provide the client with a robust completed machine that had a high throughput rate all within a strict project deadline. The preparation done in defining a robust system architecture made the commissioning process smooth and efficient. This also kept the programming from becoming unwieldy, even when controlling a wide variety of devices. 

Learn more about DMC’s Rockwell Programming expertise and contact us with any inquires.

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