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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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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To do so, DMC replaced their existing stand alone panel HMIs with a network of Ignition Edge panels running on Siemens IPCs that will function as a centralized system or independently in the case of a network outage.

Architecture

DMC replaced the client’s existing production line HMIs with Siemens Panel IPCs that run Ignition Edge. Each panel runs both the Ignition Edge server and the Ignition client that operators use to view and control the machine. Each panel is an independent unit, but also interfaces with a central server and data storage to receive software updates, load recipes, or log process data. This DMC developed architecture allows the panels to operate independently in the event of a plant to plant network failure.

Ignition

With our expertise in Ignition, DMC was able to directly integrate all of client’s Siemens SIMOTION controllers with the Ignition Edge IPC with data then being transmitted up to the central Ignition server. We tested different communications strategies and opted to use the SIMOTION controller’s built-in OPC-UA server to transmit data.

We used Ignition’s Hub and Spoke Architecture, which allows the client to have one central Ignition server and multiple Ignition Edge servers for the different lines. To link the central and Edge servers, we use the Enterprise Administration Module (EAM) and Edge Sync Services. EAM is used to synchronize data such as updates and program versions across the Edge panels so we can edit once and deploy changes to all lines across the country. Edge Sync is used to send data from the individual Edge panels back to the central server.

Conclusion

DMC’s combined experience in Siemens automation & motion control and Ignition SCADA allowed us to successfully standardized the client’s panels, recipes, and the automation programs themselves. The client can now centrally monitor and manage all of their lines without the need to maintain code and data for each facility and machine.

The system DMC developed allows the client to store, maintain, and compare their recipes without having to go to every individual line. The client can modify those recipes from any where in their plants, and can now maintain a higher level of consistency and quality for all of their products. And with the architecture DMC deployed, the panels can work together with the central server, or, in the instance of a network failure, may fail over to the local Ignition Edge HMI.

The client is continuing to gain extra benefits from this centralized system. After project completion, they were able to replace an additional datalogging system with Ignition’s built-in solution: the SQL Bridge Module. They are also working to integrate Active Directory authentication to standardize operator login credentials across all panels in the plant. These additional advantages of Ignition were only realized after the system was already deployed.

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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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To meet the aggressive customer timeline, DMC leveraged two major tools available with the Siemens Brewing Template. The first tool was Siemens TIA Openness, which allowed DMC to rapidly generate the base control module, or device, layer of the program. By doing this, DMC was able to go from zero to full manual control of devices in a matter of days, as opposed to weeks. The second tool leveraged was SiVarc, which allowed DMC to automatically generate HMI screen objects based off of the control modules created through the Openness utility. The use of SiVarc greatly reduced HMI screen development time, allowing DMC to focus on the less automated portions of development (for example, sequence creation).

To allow for operational flexibility in running and creating new recipes, DMC implemented an S88 software structure to create separation between the equipment and procedural layers. Because of this, the system can be run in three different modes of operation: manual mode, semi-auto, known as, equipment module mode, or full automatic batch control mode.

Learn more about DMC’s Siemens partnership and our work in the Food and Beverage industry. Contact us with any project inquiries. 

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The client came to DMC with a request to enhance the reliability of their machine controls. Their original automation platform was not well-known and was running on a PC as opposed to a PLC. If the computer crashed, it would stop production. At a facility that processes close to 1000 cuts an hour, 5-10 minutes spent rebooting a system could result if substantial losses in output. DMC converted the machine to a Siemens S7-1500T PLC with S120 Servo Drives while maintaining all the original system functionality. This not only allowed for improved reliability but also guaranteed global technical support with Siemens integrators located worldwide. These features aided our client in selling to their end customers and speed up future commissioning.

In addition to enhanced reliability, DMC built a flexible code base with parameters that can be adjusted directly from the HMI. This meant that the machine could be easily modified to create custom-tailored solutions for each factory installation.

Within a year of commissioning the first machine, DMC has now built 5 additional machines that are deployed around the world. With ongoing requests coming from the end clients, DMC’s flexible code is quickly modified to meet customer’s requests. One example of this is when DMC was able to install an entire machine in one day. This short deadline was able to be met due to the benefit of consistently using one platform throughout the machine.

In the meat industry, precision while cutting is a high priority. When a few inches in the wrong place could result in wasting an expensive cut of meat, DMC needed to be able to increase accuracy. By integrating the Kinematic Technology Object into the client’s machine, future users can make more complicated cuts with increased accuracy.

Learn more about DMC’s work in the food and beverage industry and our Siemens expertise. Contact us for any project inquiries. 

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We upgraded the multi-axis motion control system from stepper motors to servo drives for faster performance and higher throughput. We configured the integrated safety PLC for e-stop buttons and machine guarding.

Further, our team revamped and redesigned the HMI layout to make it more user friendly. We added a configurable dashboard on the home screen to give the user a clear picture of what’s going on within the system. We added an alarm and event log for troubleshooting.

We revamped the recipe configuration features to fine-tune and optimize machine performance for each type of cannabis strain.

After launching the product to the market, DMC helped Bloom Automation commission and test the initial batch of machines being sent to the first customers. We trained Bloom’s team to make sure they understood the system. We are continuing to provide ongoing support and troubleshooting.

Learn more about DMC’s work in the cannabis industry.

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The customer had a system that was in danger of failing completely. The system was not only outdated, but any offline node would take down the entire system and was no longer a supported platform. In fact, the system completely stopped working the day the demolition of the upgrade began. The customer needed an integrator who could not only manage a system upgrade that was three years in duration but also handle the very challenging mechanical and electrical requirements of the system. DMC’s multi-disciplinary team was a great fit for this project.

Our engineers started with a complete system of functional requirements and design phase. We used the complete specifications to develop the SCADA, PLC, and data acquisition components of the system.

DMC’s team completed the implementation of the system from start to finish and met the go-live date required for the client’s operational needs.

We performed simulation and complete FAT (factory application test) prior to the delivery of the system on-site to reduce time and expenses onsite. This was critical to the success of the project since the location and facility requirements are much more challenging to “test in the field” methodologies. Once the simulation was complete, we went on-site and installed the system.

We programmed Siemens S7 1517 TF PLCs to control the system, where there were over 20 axes operating on one PLC.

Reliability Improvements

This system now has much-improved reliability. With the old system, if one node failed, it would take down the entire facility. DMC built a new, modular system such that a single failure would not take the entire system down.

Native Redundancy

 We used WinCC OA as the SCADA user interface in a redundant configuration which allowed the continued operation if one server fails. The redundant configuration also allows the ability to update the system without taking it offline. The redundancy appears completely seamless to the user. Deploying the system as redundant was a trivial change to configuration files. This allowed us to perform the development against a normal non-redundant system and seamlessly implement redundancy during FAT. The system now runs seamlessly with either server active.

Further, the WinCC OA SCADA system provided Siemens native driver support as well as OPC UA server and client support.

Data Acquisition System

The client’s requirement of collecting system position data at 10 kHz is outside the bounds of what is possible in a PLC based system alone. As a NI Alliance Partner with extensive LabVIEW expertise, we were able to program a NI cRIO data acquisition system to capture this high-speed data. We integrated the NI cRIO system with the Siemens PLCs with PROFINET, the native Siemens PLC communication protocol. By connecting the encoder feedback to the cRIO and the cRIO to the Siemens PLC via PROFINET, we were able to collect the required 10 kHz encoder data and provide lower speed data to the S7 1517TF PLC via PROFINET for closed-loop position control.

Learn more about DMC’s Manufacturing Automation and Test & Measurement services. Contact us with project inquiries.

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Managing Production Demands

The green tire ASRS manages production demands in several ways. The first primary servicing maintains steady infeed from upstream tire building conveyors. As tires enter the system, serial number, model number, and storage operation data are received from plant MES, dictating how the ASRS should handle individual tires. Tires can assume three status indications from the infeed: store, reject, priority bypass. The ASRS processes the tires, palletizing like tires for storage in the high bay, rejecting tires for quality reasons, or bypassing priority tires to meeting curing demands.

Another mechanism by which the ASRS services production demand is automated retrieval. For pallets stored in the high bay, the plant MES system is capable of scheduling and requesting retrieval of specific tire types to service curing and order needs. The plant MES queues requests and then the green tire ASRS dispatches the primary pallet handling platform and gantries, all while balancing inventory recall with infeed demands. 

The green tire ASRS operates on Siemens controls platforms. Utilizing customized PLC and Motion control software, the central control systems provide support for product tracking, robotic dispatching, and operator interfacing. The flexibility of Siemens control platforms was critical to improving system functionality, reliability, and safety. The Siemens toolchain aided significantly in supporting a multi-developer team, aiming to deliver in a high demand production environment.
 

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DMC started with the motion control, as this was essential to the project’s success. DMC developed and validated a driver set for controlling a single motor using the Ethernet communication protocol. This driver was then applied to the other motor, and independent speed and position movements were proven out on the system. The next major requirement was synchronous control of both servos. Using the driver sets previously mentioned, DMC proved out tight synchronous control of the two servos that met the system requirements for precision without resorting to mechanical gearing of the servos.

Once the motion control software was complete, we developed an application to integrate the motion control with the other major IO of the system, which include analog and digital inputs and outputs. A screenshot of the application is below. DMC built the user interface leveraging the cRIO’s embedded user interface, which saved the cost and complexity of using a PC to simply host a user interface for the system. A separate thread handles any user interaction by constantly listening to any activity from the UI.

Logging of real-time data was added to the cRIO so that the client’s engineering team could review the data in post-processing. To log data at fast rates, DMC chose a TMDS file format for quick and efficient data streaming to disk. This efficient streaming is important when logging is done on a cRIO rather than a PC, as the cRIO has significantly less available disk space than what we typically expect from a PC. The highly efficient TDMS file storage allows for optimal results in these more limiting circumstances.

After setting up the manual control of the entire application, DMC took the last step to automate the process. Using the manual control application that had already been built, DMC added a sequence configuration tool that allowed the user to set up an arbitrary order of operations for the system to sequence through using a basic ini file format. The advantage of this sequence configuration was that the client could write sequences (with the help of a syntax example) at their desk and deploy the sequence files from their network without having to manually control operation from the UI. 

DMC added validation checks that examined the validity of sequence steps before execution to prevent beginning a sequence that would cause the system to go into an error state. This is valuable to the client, as it allows them to create and execute custom sequences that can be run multiple times without the need to manually interact with the UI for the full duration of every test. Custom sequencing allows for flexibility in use as research and testing requirements change over time.

While the sequence is running, the operator may choose to pause or abort for any reason. The software also has real-time fault limit checking that is configurable in the system settings for all digital and analog inputs to the system.

Overall, the cRIO-9038 provided the perfect platform for high-speed data acquisition and synchronous motion control combined with an embedded UI for a convenient and easy-to-use front end. With DMC’s solution, our client now receives more accurate data on their products, and running tests is easier than ever with this automated, custom test recipe solution.

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