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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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.

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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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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.

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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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Our engineers commissioned the skid and wrote batch reports on a machine set up with Siemens WinCC 7. We reorganized some of the client’s screens and tracked logging in to ensure permissions were secure. With traceability of high importance, DMC took all the key process information and recorded them. This included any types of alarms or deviations occurring during the process. At the end of a run, DMC printed out the batch report using built-in WinCC reporting our engineers wrote while on site.

DMC got the skid up and running after altering the testing process to monitor the flow rate of the system as opposed to looking at its pumps as they were fouling. With our automation expertise, experimentation, and refinement, we stabilized the pumps needed to run the machine.

We reviewed all of the validation documentation, assisted in the execution of it, and accounted for any deviation. While onsite, our engineers worked on the machine in clean rooms. The project involved lots of mixing, and there were tight ratios we had to work with. With our process control experience, we successfully monitored the mix between the multiple different types of fluids.

After our work on the first machine and ramping up on the process, the client asked us to act as their process experts on the commissioning of a second machine at another location.

Our expertise in Siemens HMIs and WinCC 7 and our overall Automation experience led us to successfully commission both projects.

Learn more about DMC’s Process Automation, and contact us today for your next project.

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To help interface these drives with DMCs code, technology objects were implemented. Each axis was primarily controlled by a position axis technology object with a synchronous axis technology object added in to accommodate the second VFD being used to move the Y axis.

Since the PLC was a 1500 series and not a 1500T, we were not able to absolutely gear the two Y axis VFDs to one another. DMC circumvented the potential issue by relatively gearing the two axes at a 1 to 1 ratio. Using this setup, we were able to move gantry to very precise points within the system at speeds within the end user’s requirements. If used in a system with a 1500T, DMC would have also been able to utilize Siemen’s kinematics technology object.  This would have allowed for the creation of Cam profiles and much smoother point to point movement in the system.

Another benefit to using the technology objects is that they allowed DMC to easily incorporate hardware stops to the program. In the limits configuration for the technology objects, the programmer can directly set digital inputs as end of range limits for a given axis. These limits can also be configured to be either normally open or normally closed.

By using Siemen’s built-in functionality, DMC was able to effectively meet the needs of the project and work around potential hardware limitations.

Learn more about DMC’s Partnership with Siemens as a Siemens Solutions Partner, and contact us today for your next project.

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The NFPA Publication 70, NEC, and CEC define Class II locations as those in which combustible dust may be found. The subcategory of divisions that the classes are further subdivided into defines the likelihood of the hazardous material being present in a flammable concentration.

Division 2 is defined as follows:

“In which ignitable concentrations of hazards are handled, processed, or used, but which are normally in closed containers or closed systems from which they can only escape through accidental rupture or breakdown of such containers or systems.

We used a Factory Acceptance Test (FAT) because the hazardous environment was not present. This FAT tested functionality and verified that, if someone were to open the door, the purge would be lost, and that we killed power to the entire panel. Overall, the test proves that we eliminated the risk.

Our engineers provided support in successfully completing this project the client had already started. With our expertise and programming experience, we successfully provided a solution that can operate in a C1D2 hazardous environment.

Read more about DMC’s manufacturing automation & intelligence services and contact us to get started on 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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