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.

The post Enabling Scientific Innovation Through Test Lab Automation appeared first on DMC, Inc..

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.

The post Distributed Safety System for Pilot Plant appeared first on DMC, Inc..

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. 

The post Operational Technology Infrastructure for Aerospace and Defense appeared first on DMC, Inc..

DMC began by scheduling a site visit to transcribe the current Omron PLC program, generate an I/O list, take dimensions, and create a rough functional specification for the machine. DMC also investigated the programmed Omron functions, with the expectation that most built-in functions would not be a direct translation into the new program. 

We then specified what hardware would be best suited for the project based on the client’s needs, and we decided to use Siemens S7-1511 PLC due to the high hardware availability, low costs, and string feature set. We started on the translation of the complex Omron instruction list code to ladder logic, using TIA Portal as the programming software. 

Siemens S7-1500 PLC 

DMC successfully ramped up on the SYSMAC C-Series technology in a timely manner and utilized our expertise in the Siemens platform (including automation hardware, PLC programming, and onsite commissioning) to develop a robust solution that will be maintainable and supportable going forward. 

As we moved into the commissioning of the project, DMC’s hardware subcontractor wired and replaced the PLC. DMC then started the I/O checkout and commissioning. During the I/O checkout, we were unable to read any of the sensor inputs and soon realized that the old sensors were not compatible with the new PLC. The client needed the machine to be up and running within two days, so we provided an alternative, timely solution to replacing the sensors and added relays to switch the polarity of the sensor signal.

Learn more about DMC’s Legacy PLC Upgrade and Conversion Services and contact us today for your next project.

The post Modernized Legacy Rotary Indexing Filler with Siemens S7-1511 PLC appeared first on DMC, Inc..

• 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. 

The post Automated Material Flow with B&R PLC and HMI appeared first on DMC, Inc..

DMC first worked with the client to develop a robust functional specification. Then, our UX/UI team developed screen mockups for the crane operator, which we also did the PLC Programming for in addition to the joysticks attached to the crane operator’s chair.

Our Control Panel Design and Fabrication experts from our UL Certified DMC Fabrication Studio completed the panel build part of the project. There are two panels in the system: one is the main control panel that houses the main PLC, and the other is the remote IO panel housing a separate PLC. The two loading arms share the same panels but are electrically isolated from one another. Thus, one can be powered off for maintenance while the other remains operational.

DMC’s Fabrication Studio allowed us to be flexible in hardware and lead times. We were able to use a different cabinet because it had a shorter lead time instead of being locked into the one that we were using when we needed to change the system’s design on short notice while still accommodating the client’s timeline.

Our experience with general automation construction-based projects and our experience in control panel builds led to a successful project.

Learn more about DMC’s Control Panel Design and Fabrication expertise and contact us about your next.

The post UL Certified Panel Designs for Waste Incineration Facility appeared first on DMC, Inc..

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.

The post Flexible Manufacturing with Wireless Safety appeared first on DMC, Inc..

Our engineers programmed more than ten pairs of S7-1500H PLCs, along with SCALANCE XC200 switches, that were networked in a ring topology with media redundancy protocol (MRP). We configured the PLC-PLC communication with Open User Communication using the Siemens TSEND_C and TRCV_C instructions. We also utilized BacNET, Modbus TCP, and Modbus RTU for communication with other devices on the network. For operator control and monitoring, PLC tags were exposed to the Desigo CC building management software.

DMC programmed robust sequences for the scheduled or emergency rotation of redundant AHUs, DOASs, and Chillers to ensure the high availability of the system. We used the Siemens Open Library extensively for common sensors and devices, as well as PID control.

During commissioning DMC drove device testing, subsystem testing, and PID tuning. At the conclusion of the project, we heavily supported a stringent acceptance process to ensure that the system met the functional and cybersecurity requirements of the end-customer.

DMC’s expertise in Siemens PLC programming, our expertise in system diagnostics and troubleshooting, and our detailed and timely communication were essential to the success of the project. 

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

The post High Availability HVAC System using Siemens S7-1500H Controllers appeared first on DMC, Inc..

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.

The post Pharmaceutical Manufacturing Automation with WinCC OA appeared first on DMC, Inc..

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.

The post Increasing Efficiency and Safety of Battery Assembly Line appeared first on DMC, Inc..