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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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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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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• 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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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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• Conveyor system with automatic buffering/transfers.
• Data tracking using RFID readers and custom PLC logic.
• Vision inspection for pass/fail of parts.
• Automated reject handling based on pass/fail.
• Operator interface station to perform manual intervention.

Automated storage and retrieval system.

• Central buffer for all work in progress parts.
• Storage and retrieval of radios accomplished via integration with robot arm.
• Part data determined via RFID, data stored in custom database.
• Parts delivered to and requested from buffer fully automatically with AMRs – no operator interaction needed.

Packaging station.

• Robotic packaging system to place parts into boxes, place boxes onto pallets, strap pallets, and deliver to warehouse management system.
• Automated conveyor infeed of parts, boxes, and other consumables.
• Flexible assembly sequences based on needs of specific part.
• Integration with WMS and MES systems for fully automated sequences.

DMC programmed each machine using B&R’s PC based PLC platform.  Each machine had its own Industrial PC running both Windows for the HMI and B&R’s Automation Runtime for the PLC. Operator interface was via MappView on a touch-screen panel PC. All PLC and HMI programming was done in Automation Studio, a text based IDE.

Automation Studio files are text based and human readable. Because of this, DMC was able to use a full git based development workflow during both offline and onsite development. This included automated merging features created in parallel by different developers, as well as the ability to resolve merge conflict on a line-by-line basis. This allowed quicker development and higher quality code due to efficient code reviews.

DMC integrated a large variety of communication protocols and devices for the project. This included OPC UA, PROFINET, POWERLINK, X2X, zebra printers, SQL databases, and various systems for MES, AMR, and WMS communication.
 
The communication backbone for the MES, AMR, and WMS systems was OPC UA. B&R’s OPC UA forward platform allowed DMC to effectively communicate with all three systems via OPC server and client methods. Each of the tools automatically requests both work in progress parts from the buffer when needed as well as additional consumable materials when low. Once a part is completed in one tool, requests are automatically sent for AMR pickup at the tool output. These automatic requests for delivery and pickup increased the plant’s efficiency and don’t require operator intervention.

To allow for efficient commissioning, DMC conducted extensive OPC UA method testing against a simulated MES environment before going onsite. This included simulated conveyor data transfers, part tracking, and failure conditions. Once onsite, DMC implemented extensive logging for OPC interactions to assist in debugging unexpected behavior. This logging was available to plant operators via the HMI, allowing DMC to quickly close the loop without having to manually go online with the system.

Overall, our expertise in B&R programming, OPC UA, and MES Integration led us to successfully provide the client with an automated assembly line system that allows the client to respond to changes easily.

Learn more about our PLC Programming expertise and contact us for your next project. 

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WinCC OA SCADA Configuration and Integration

DMC utilized WinCC OA to provide a centralized interface for plant control and monitoring. DMC utilized Redundancy in WinCC OA to meet the high availability requirements of the plant. A custom user interface was developed utilizing high efficiency HMI design principles. This system provided key features such as data acquisition and archiving to Oracle database, alarm monitoring and SMS/email notification, and audit trail functionality for regulatory compliance (21 CFR Part 11).

Electrical Design and Build

DMC worked with partners to design and build electrical panels for a variety of systems. The panels met the client’s requirements including NEMA, UL, and safety requirements. As a close Siemens partner, DMC worked with Siemens application engineers to select the hardware necessary to meet the client’s needs.

PLC Programming

DMC designed and implemented PLC programs for the facility’s manufacturing utilities and monitoring systems. Successful integration required close coordination between DMC and our client’s process and controls engineers.

OEM Equipment Integration

DMC integrated dozens of OEM vendor systems into WinCC OA for data acquisition and monitoring. We reviewed vendor code and integrated a variety of systems utilizing WinCC OA’s extensive communication drivers to communicate with many different platforms (Siemens, Rockwell, GE iFix, Wonderware/AVEVA, etc.).

Documentation and Regulatory Compliance

Throughout the project, DMC followed Good Manufacturing Practice (GMP) guidelines to ensure quality standards and meet regulatory guidelines. We generated software and hardware test plans during the development cycle, wrote qualification documents for installation and operation qualification, and provided onsite support for equipment commissioning and qualification.

Learn more about DMC’s WinCC Open Architecture Development expertise and contact us today for your next project.

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Using the TwinCAT 3 HMI Recipe Manager, the solution was configurable to a variety of printing applications and production lines. It supported modes for high-speed and low-speed application and allowed operators to easily configure and support a variety of product geometries. Additionally, it allowed for the application of labels without stopping conveyor motion.

DMC provided software for several identical programs. The client sent DMC engineers the necessary hardware. DMC engineers then loaded the software and shipped the hardware directly to the end customer with no commissioning required.

DMC engineers have created a blog series detailing this process.

Learn more about DMC’s TwinCAT3 programming experience and contact us for your next project.

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The client’s set of two of Original Equipment Manufacturer (OEM) machines utilized different code bases but worked together to create oral tablets in batches. One machine mixed the dry ingredients to create a homogenous powder and the second machine then pressed this powder into tablets. Each machine was controlled by a Programmable Logic Controller (PLC) and ran separately with different recipes and configurations.

DMC Solution: Continuous Mixing and Pressing

DMC utilized the WinCC OA Supervisory Control and Data Acquisition (SCADA) system to help the client transition from this manual batch process to a more automatic continuous process. The WinCC OA program gives users an overarching view of the system and sends command signals and recipe configurations to and from both PLCs to control both machines as a unified system. This allows users to configure and control the entire process from a single interface rather than from two separate HMIs.

Centralized Recipe Management

In addition to centralized control, DMC utilized WinCC OA’s flexible database system and scripting to create and implement a centralized recipe system. Instead of recipes being configured and maintained separately on the OEM PLCs, users now can create, modify, and manage recipes for the system via a single interface. Selected recipe parameters are sent to the individual PLCs where they are implemented and run with the OEM code.

Our proficiency and expertise with WinCC OA led DMC to successfully convert the client’s batch processing system with separate machine controls into a continuous process with sequencing and recipe management controlled from a single interface.

Learn more about other HMI & SCADA solutions DMC has delivered to clients and contact us to get started on your next project.

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The HMI provided real-time data and warnings for the tool, as well as logs and visualizations for quality control for each banding cycle. The PLC provided high-speed data collection for pressure, torque, speed, and sensors during each tension and cut cycle. The HMI then wrote that data to CSV files on an SD card. The most recent log was shown on a XY plot, and any log was available to be downloaded to USB.

Learn more about DMC’s Siemens S7 PLC Programming expertise and contact us for your next project. 

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