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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Software Conversions 

DMC utilized Rockwell’s RSLogix migrator tool to convert old PLC5 programs to Studio 5000. We developed custom tools to automate the IO mapping between the new hardware and old program tags. DMC also developed an interim solution to maintain data exchange between legacy and upgraded systems until all upgrades were complete.

Electrical Design and Build 

DMC performed multiple site visits and worked with existing drawing sets to create new drawings and spec appropriate hardware for upgrades. Allen-Bradley conversion hardware was used to significantly reduce installation time and risk, since existing field wiring would not have to be modified. Rockwell’s Integrated Architecture Builder (IAB) was used to assist in the BOM generation process. Special consideration was given to space constraints of the existing panels, and in some cases, new enclosures were installed. DMC procured all hardware, which was then assembled in its panel shop.  

Hardware Testing 

To ensure that all hardware was functioning properly prior to installation, each system was powered on and checked at DMC’s panel shop. This included flashing firmware, setting IP addresses, checking network functionality, and testing each individual IO point. To facilitate the checking of IO, DMC developed custom test boards for each unique combination of IO module its’ conversion hardware. 

Onsite Installations & Commissioning 

Electrical prework such as running new network and power cables, panel cleanup, and hardware replacement was performed prior to power down to minimize downtime. By utilizing Allen-Bradley conversion hardware, the electrical work was frequently completed in less than three hours. The conversion hardware and previous bench testing allowed for functional testing to begin as soon as the system was powered on. Throughout the installation process, DMC provided onsite support and troubleshooting to ensure the new system was functionally identical to the old system. 

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

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By leveraging Rockwell’s PlantPAx libraries and tools like Application Code Manager, DMC was able to meet the client’s aggressive commissioning timeline while also keeping the project on budget, demonstrating DMC’s core values of “Share Information” and “Make Things Happen.” 

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

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1. Design and implement control systems to control the pressure and flowrate of process fluids used to create test conditions for devices under test.  
2. Exchange process data, test configuration, and status information with an external data acquisition system.  
3. Provide intuitive and detailed test configuration UI, allowing for wide range of test conditions and profiles.
4. Standardize programming with tested and validated control strategies to minimize operational risk and enhance troubleshooting capability.  
5. Minimize commissioning time and risk.  

Phase 1: Requirement Analysis and Planning  

• DMC conducted numerous onsite and offsite meetings with the end customer and various external stakeholders to establish design objectives and requirements.  
• From these meetings, we identified the required hardware and software features needed to meet our customer’s overall design objectives.  
• We conducted several rounds of design review with the facility end users to refine the user workflow for both operating the facility and processing test results.
• The final design of the hardware and software was translated into a Functional Specification document. All sequence steps, permissives, interlocks, alarms, and HMI wireframes were captured in this document for reference by both the DMC software development team as well as the facility end users.  

Phase 2: System Design and Development  

• PlantPAx 5.0 Selection: Given the need for highly performant process control and well-tested, robust programming blocks, DMC selected the Rockwell Automation P-Processor (1756-L83P) to control the facility. The selection of a P-processor allowed us to leverage the full PlantPAx v5.0 library, which comes built into the process controller’s firmware.  
• Application Code Manager (ACM): To allow for rapid development, consistent programming, and to minimize programming errors during implementation, DMC used Application Code Manager (ACM) to generate the base code for the project. This was especially important in the early phase of the project, where DMC aimed to prove out the user workflow for the facility even though the specifics of the facility’s field equipment were still being finalized. Even large changes to the list of field devices were easily propagated to the code throughout the development process, using ACM to quickly re-configure and push changes to the project.  
• FactoryTalk View SE: DMC selected FactoryTalk View Site Edition (SE) as the HMI platform for the facility. When used in tandem with the PlantPAx library, FactoryTalk View allows for rapid development of facility overview screens, since faceplates for each PlantPAx process object come pre-configured. The ability to quickly adapt screens and showcase the deep HMI feature set within the PlantPAx ecosystem gave our customers a high level of confidence in their new system throughout the design process.  

 Phase 3: Simulation and Testing  

• FactoryTalk Logix Echo: DMC employed FactoryTalk Logix Echo for emulating field devices and for advanced simulation of process pressures and flowrates. This allowed our development team to create a virtual environment that mimicked the real-life process behavior in the facility. Using simulation code running on Logix Echo, the team conducted extensive testing of our control strategies and sequence logic. We were even able to validate cross-platform communication to external software systems by connecting the simulated Logix Echo controller to FactoryTalk Linx Gateway’s OPC-UA driver.  
• Scenario Testing: Prior to field commissioning, DMC simulated various operational scenarios and validated system responses. This included normal operation, fault conditions, and emergency shutdown procedures. A wide range of test conditions and configurations was simulated, which helped identify the upper performance limits of the process system and decreased commissioning risk.  

Phase 4: Implementation and Commissioning  

• Staged Deployment: We coordinated with the end user team and external stakeholders to create a phased testing and acceptance plan, designed to ensure the system was functional at all levels of control—from individual devices, to process subsystems, to the entire facility.  
• Training and Support: We provided comprehensive training to the plant’s engineering and operations team on the new system, ensuring they were well-versed with the new features and functionalities. This included detailed operations and maintenance manuals on the system, a three-week structured onsite training course, and ongoing coordination meetings with the end users.  

Conclusion  

The successful implementation of the Rockwell PlantPAx P-Processors, Application Code Manager, and FactoryTalk Logix Echo for our client’s flight test facility showcases DMC’s expertise in deploying advanced control systems. The project not only met the client’s immediate needs but also positioned them for future growth and technological advancements. Our approach to leveraging modern tools and methodologies ensured a smooth roadmap to a fully mission-capable test facility and delivered substantial operational improvements over the legacy facility. 

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

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Network Design

DMC designed a robust and scalable network across several different campuses and buildings using the Converged Plantwide Ethernet (CPwE) network design guidelines. The CPwE guidelines are a set of best practices published and maintained jointly by Rockwell Automation and Cisco.

The design limits noisy broadcast inherent to OT systems by applying the core design principle of 1 VLAN to 1 Subnet to 1 Cell/Area/Zone (1:1:1). Network segmentation allows for more manageable inter-network communication between different areas.

DMC engaged early into the facility and network design process to gather client requirements and information about machines provided by OEM suppliers. We incorporated and iterated on the OEM system designs and supported protocols to create a fully connected facility between DMC provided PLC/SCADA systems and OEM systems.

We selected network equipment that provides Power over Ethernet (PoE) to power and connect client provided cameras. We saved all recorded videos directly to client provided Network Video Recorders (NVRs). 

Server Virtualization and Provisioning

DMC utilized client functional requirements to design the software stack required to operate their facility. We selected a rack mount server with appropriate CPU, RAM, and storage capacity to support the software stack. We also allocated additional space to allow the user to increase the RAM and storage of the server as the system naturally expands over time.

DMC provisioned the servers using Microsoft Hyper-V and several different VMs to separate out specific applications and services following vendor recommendations. We joined all Windows based VMs to a domain controller to allow user management for distributed systems using active directory.

Deployment

ThinClients deliver the interface for system control to operator stations in several different buildings, oftentimes hundreds of meters from the process being controlled.

Multiple monitors at each operator station deliver not only the full SCADA interface for system control/monitoring, but also multiple camera feeds for visual monitoring of processes and areas.

Conclusion

DMC designed and delivered a system that allows operators to safely control and monitor processes occurring kilometers away using fully integrated operator workstations. Our incorporation of OEM systems with a larger OT network and virtualized server stack allowed us to create a scalable and reliable system that will be used for many years to come. 

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Architecture

Many of the existing pieces of equipment either had no PLC or had a PLC that was obsolete and no longer supported. DMC selected upgraded PLC hardware and drives to modernize the existing equipment and provide PLC control to equipment that was previously only run manually.

Safety System Implementation

Prior to our work, each piece of equipment could only be run standalone. As a part of this project, the equipment needed to either run standalone or be integrated into a single production line depending on the product they were going to make. In order to safely integrate the equipment into a single production line, the e-stop associated with each piece of equipment needed to be added to a single safety zone.

To accomplish this, DMC specified and procured safety PLCs, safety I/O cards, and PowerFlex 525s with integrated safety. This allowed us to use programmable safety logic and, depending on the selected production line configuration, programmatically add or remove a system’s equipment from the global estop zone. This safety communication was done wirelessly to allow for the varying line configurations. 

Panel Build

For some of the equipment, an additional panel was needed to add controls or to fit the additional safety hardware if the original panel was out of space. Our Control Panel Design and Fabrication experts from our UL Certified DMC Fabrication Studio stepped in and created Rockwell-based panels for the pilot plant. DMC’s in-house electrical design team, along with a trusted partner, provided the modified and new electrical schematics required for this project.

Since we were working with older equipment, new information was often uncovered during the design upgrade. DMC’s Fabrication Studio allowed us to change the system’s design on short notice while still accommodating the client’s timeline throughout the project.

Conclusion

DMC was flexible throughout the project as design changes were required, and we worked through global supply chain delays.

We left the client with a modular production line with an integrated safety system that contains equipment capable of running standalone or as a configurable unit. We also provided them with upgraded and modernized Rockwell hardware for new and existing enclosures.

DMC is a Rockwell Gold System Integrator. Learn more about our Rockwell expertise and contact us for your next project.

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Our engineers reprogrammed and re-commissioned the three most inefficient cells within the client’s proof of concept battery pack production line. We re-wrote the programs’ PLC code, re-created HMI screens, and better integrated existing technology.

HMIs

HMI screens and objects were re-developed from scratch using high performance HMI standards. DMC developed additional client-specific standards and reusable screen elements in order to improve development efficiency and ensure UI/UX consistency between stations. The resulting HMI provided for a more intuitive and streamlined interface for operators.

TR88 (PackML) Structure

Engineers implemented a limited scope model for the program that allowed the core components to be reused from machine to machine. We implemented a TR88 program structure (PackML) throughout the three stations’ Rockwell Automation PLCs. This provided operational consistency to the machines within the line.

MagneMotion

During the rewrite, DMC added in more functional Rockwell Automation MagneMotion control to the system that had been reliant on operator intervention for moving product between stations. Improvements included more robust product movement functionality and better vehicle recognition upon MagneMotion path reset. Overall, DMC ensured the motion system that carried the parts around worked smoothly and more efficiently.

Additional Operational Efficiencies

The new cell changes also improved management and supervision capabilities. Better part ID and status tracking served to improve and streamline MES traceability. Furthermore, machine status tracking on the PLC allowed for the logging and display of key Overall Equipment Efficiency (OEE) metrics and cycle times.

After implementing the re-written code to the three relevant cells, DMC provided continued production support for the entire assembly line to further increase line uptime and efficiency.

DMC ultimately delivered production line improvements that met customer requirements and  proved significantly easier and efficient to operate. We brought our programming, commissioning, and supporting expertise to the battery pack production line and improved runtime, machine usability, ease of training, safety, and overall efficiency.

Learn more about DMC’s Automotive Manufacturing Programming, Integration, & Testing and contact us today for your next project.

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We made sure to program our automation system with an expandable and modular framework in mind. Therefore, the system can be easily modified in the future to flexibly accommodate other processes with less engineering impact—making this a facility that can grow with our client. 

Overview

This large-scale project can be divided into three main components. First, DMC used our application development expertise to write multiple drivers. These drivers were responsible for integrating our customized automation system with their existing pieces of various nonstandard lab equipment. Next, DMC designed a custom Ignition SCADA system, which served as the user interface (UI) for the entire laboratory and the database infrastructure (mainly for CLIA compliance). Lastly, DMC developed and built the automation system itself, which will be the focus of this case study.

Since the facility is so massive and the testing process is very complex, the testing line needed to be as flexible as possible. Therefore, the line was divided into work cells in which a small step of the process was performed in each. To return a test result, each sample needed to pass through every cell.

Transport System

These work cells were spread throughout the facility and connecting them was a MagneMotion transport system with three work groups. The samples travelled along this system to each work cell. DMC then designed Control GuardLogix PLCs to act as Line PLCs for the transport system—i.e., responsible for routing the samples and keeping track of where they are in the testing process. We also utilized Rockwell’s independent cart technology in this system to provide a standard architecture for how samples are routed throughout the facility. With thousands of sensitive biological samples traveling about a mile from start to finish during the testing process, it was critical that we had a system robust and reliable enough to handle so much data.

Due to the nature of certain lab operations, the system was separated between two laboratory rooms. DMC connected the rooms through an automated MagneMotion elevator to convey movers from one area to the other. The custom-designed elevator featured independent, synchronous Allen Bradley servos to seamlessly connect different levels of MagneMotion track.  

In addition, DMC programmed Compact GuardLogix PLCs for each work cell to control its equipment and properly execute its testing step. All fifty line PLCs and three cell PLCs used PackML architecture, which standardized information between work cells to ensure all machines were functioning in sync with each other.

In total, this massive project included thousands of motors, hundreds of paths, hundreds of nodes, and over ten node controllers. With our MagneMotion experience and wide variety of expertise, DMC was able to provide Ginkgo with comprehensive PLC, SCADA, and application development solutions to process over 100,000 samples a day. DMC is proud to have been part of Ginkgo’s effort to expand COVID testing and help develop a sequencing facility that can be used in many different ways for years to come. 

Learn more about DMC’s manufacturing automation expertise and contact us today to get started on your next project.  

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The machine that DMC commissioned and programmed uses an indexing walking beam and pick-and-place arms controlled by Rockwell Kinetix drives. It performs processes such as tub and rod feeding, welding, tube cutting, pad printing, print inspection, full tube lubrication, and various bending operations.

Offsite Programming

In order to get started, the customer provided CAD models, timing charts, and videos of the machine and operation. To align with their standards, the client also provided the template code that we were to build the program off of. DMC compressed ~16 weeks of engineering into just 6 weeks by quickly ramping up a large team. At the end of the offsite phase, DMC had developed the PLC and HMI program for the entire machine. DMC also dedicated additional time to improve the outdated HMI graphics used in the template project.

Onsite Programming

When DMC arrived onsite, our engineers also supported the customer in bringing their electrical and pneumatic system online, completing the IO checkout, and station debugging. We then continued to full machine operation to ensure that the machine met cycle time, uptime requirements, and quality checks.

Additionally, the welders and the pad printer were completely new to the client. As such, DMC spent a portion of our onsite time assisting the client with setting up and testing the new hardware.

Team Collaboration

Collaboration was key to success for this project. DMC engineers were in constant contact with the client’s mechanical designers, project managers, and controls engineers to help the project go smoothly. During the onsite phase, we worked around mechanical rework, client schedules, and required runs to effectively and efficiently commission the machine.

Handoff

After the onsite portion of the project, the client decided that it would be cost-effective to use their own internal controls engineers to go to the client site for site acceptance testing. DMC engineers did an extensive ramp up with the client engineer in order to ensure project success.

Overall, our Rockwell expertise, ability to meet tight timelines, and client collaboration allowed us to successfully complete this project.

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

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The client needed a barcode with calibration curve parameters created and printed to adhere with ISO 15415 medical standard for quality. DMC was tasked with integrating an in-line printing system into the client’s existing line that made PoC cartages for measuring levels of certain biomarkers in blood. 

Each printed label needed to have a unique serialized barcode with calibration parameters and checksum. DMC made a custom .Net application using BarTender API to create a unique 2D label for every unit with the ability to show a print preview on the HMI. With the units going through the printer at a rate of two units per second, there needed to be constant communication with the printer to create a different barcode each time it printed.

 
Omron HAWK MV4000 and Zebra ZE500 Print Engine

Bar codes in the medical industry have a different quality standard that must be met when printing labels. Different inline label printers were researched and tested for quality, speed and performance. There were performance issues with laser and VideoJet printers and in the end, Zebra ZE500 Print Engines printers were used for printing barcodes on cartridge labels. To ensure the quality of the labels, DMC used an inline MV4000 OMRON Vision system to decode each barcode printed on the cartridges, verify data and perform grading checks for ISO 15415 quality standard

Learn more about DMC’s PLC, HMI, and Application Development solutions. 

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