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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Monitoring Distributed Systems

Having previously switched monitoring services for their cogenerators several times, the client had around 250 cogenerators in the field running on different platforms. This meant that monitoring crews had to collect data from disparate apps by navigating through a tangle of user interfaces and systems for various portions of their business operations.

WinCC OA was selected as the new control system to introduce a more coherent system for tracking and maintenance. This also provided the possibility to unite both future and existing systems under a single umbrella. Given the scale of the operations, WinCC OA’s native support of distributed systems was well-suited to handle data over a large geographic range in a heavily-customized fashion. DMC’s goals included facilitating flexible setup and management of hundreds of sites in bespoke configurations across state lines.

Initially, DMC created an example interface and configuration for a single type of cogenerator generator. To do this, we developed a system to configure a new PLC and generator through a simplified menu that dynamically adds a new cogenerator to a site and populates its data. This reduced the process of setting up monitoring for a new generator to just a dozen mouse clicks and allowed the customer to easily deploy the system to arbitrarily large counts onsite and arbitrarily large site counts.

Monitoring Load Modules

Building on these successes, DMC extended the cogenerator monitoring framework to the other core component of the client’s cogeneration systems – the load modules. DMC worked with the client to generate a standardized set of definitions for hot water loads such as domestic hot water, space heating, and others, built on a repeatable set of pumps, valves, heat exchangers, and other components  These new modules and the existing cogenerator modules were then aggregated onto a configurable site diagram with itemized representations, pass-through of legacy overviews, and a user-customized overview. The fully WinCC OA-based system allows customizable configuration of the cogenerators and the loads with a clear path forward for new device and module types. Benefits of this system include rapid deployment, rapid load type definition and development, automated data display for the entire site, and fully-integrated generator and load control.

Employee Training

As part of this effort, the client’s employees trained with DMC to gain skills to manage their own development within this framework. This enabled the client to increase responsiveness to new initiatives or requirements and extend the existing architecture to any incremental device or design changes. They were also better equipped to support and design for further integrations, including upcoming work on new cogenerator types and site configurations. They were able to gain confidence in their knowledge and DMC’s support when it comes to approaching customization and maintenance of the system.

Future Developments

Due to the level of success with this project, DMC continues to support high-level developments on this system. Current upgrades include more configurable options on cogenerator interfaces, improvements to set-up templates, and the integration of new varieties of loads, site configurations, and custom PLC drivers with WinCC OA. We’ll be integrating some of the styling from the WinCC OA Open Library developed by DMC.  

Learn more about DMC’s partnership with Siemens.

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The various hardware and software are listed below:

1. Allen Bradley PLC5 with GE Fanuc HMI panel and Cimplicity HMI program
   • Upgraded to S7-300 PLC and 12” Comfort Panel
2. Siemens S7-200 PLC with MP Panel
   • Upgraded to S7-300 PLC and 12” Comfort Panel
   • Program upgraded to TIA Portal v15
   • Controlled drive over Profibus
3. Siemens S7-300 PLC with MP Panel, programmed with TIA Portal v12
   • Upgraded to 12” Comfort panel
   • Program updated to TIA Portal v15
4. WinCC Flexible RT SCADA system
   • Upgraded to WinCC Advanced in TIA Portal v15

After upgrading each individual system, the 3 PLCs, 3 HMIs, and SCADA system were all combined into a single TIA Portal V15 project. This combination allowed for troubleshooting/editing of the code from a central location, as opposed to having multiple projects for each of the panels.

The customer also requested the ability to go online with/edit the code from multiple computer stations on their internal network. However, they only had a single TIA Portal license. DMC set up a license server that allowed sharing of the single TIA Portal license between multiple engineering computers. Therefore, numerous locations onsite could view the code.

DMC provided the client with an easy to use, centralized control system that has decreased downtime and allowed for extremely easy troubleshooting and editing. We met the one week install timeline as well. We were able to meet this quick install timeline by doing extensive testing of the panel and PLC before going onsite. The client was extremely satisfied.

The client also had DMC come back onsite to do additional training after the project and said that the system is more reliable than it was in the past. 
 

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The Indusoft HMI screens were updated and standardized between machines where possible to help minimize operator training time. DMC added additional fault handling and servo drive status displays to facilitate maintenance of the machines. Additionally, DMC improved the SQL reporting system to allow for more detailed record keeping, production monitoring, and process control.

Since initially reprogramming the machines at the plant, DMC has maintained an active relationship with the client. We have provided ongoing support as needed, and assist the customer in implementing new features and adding functionality as the machines are upgraded. Implementing new features has become much quicker and easier for the client, reducing downtime. 

Learn more about DMC’s experience with Beckhoff and TwinCAT3.

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Additionally, the wireless operation allowed the system to be operated without an unsightly control panel within view of the doors so that the end customer could achieve consistency in branding and an aesthetic finish.

DMC programmed and commissioned a system containing a Siemens S7-1500 PLC and Comfort Panel HMI, two SCALANCE access points, four WLAN-connected remote I/O racks with Yaskawa VFDs, and two Siemens mobile panel HMIs to wirelessly operate and monitor the doors both in automatic and maintenance modes. To achieve safety requirements, Siemens mobile panel transponders were used to ensure that the mobile panels could only be used in locations where the operator had a full view of the doors and all safety hazards (pinch points, etc).

By leveraging the suite of tools available in TIA Portal, DMC was able to efficiently and quickly develop, commission, and test the automation solution in a fast-paced and dynamic construction environment.

Learn more about DMC’s Siemens PLC expertise.

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A system to monitor all facets of vehicle operation and relay that information to a server was written by DMC using the Microsoft stack, including ASP.NET, SQL Server, and Google Map integration. The system oversees all parameters associated with auxiliary systems on a custom vehicle, including location and fuel consumption. Units on the vehicles are running Linux with networking, while the data collection was programmed in Python.

Since data integrity was a key requirement, DMC implemented a system that is capable of internally logging data if the cellular connection is severed. Once the connection is reestablished, the backend services can connect to the device to send out data. The system has second level redundancy to cache data and send it to a database if the system is offline. 

The use of protocol buffers allows for densely packed data, drastically reducing the size of packets sent between mobile assets and the server. This resulted in a considerable cost savings on the client’s cellular network.

DMC developed an entire web interface to communicate with the backend database using ASP.NET. The front end includes all user management functionality expected of an enterprise-level website. This includes the ability to configure various roles and permissions so our client’s superusers can easily administer their system.

DMC also maintains the server infrastructure on Microsoft’s Azure cloud service and manages all the cellular connectivity accounts, eliminating the burden from the client’s internal resources.

DMC’s solution provides our client the ability to offer a service that optimizes fleet operations, saving time and resources.

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Learn more about DMC’s Siemens PLC Programming Services.

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The front panel of the test station enclosure provides BNC connector jacks for all relevant data acquisition channels for easy connection / disconnection of probes/sensors.

The primary interface provides the operator with the ability to select which tests they wish to run, start and stop those tests, and configure the pass/fail grading parameters that should be applied to evaluate the performance of the device under test (DUT).

After each strobe light or audible alarm synchronization test is completed, the test system evaluates the data acquired during the test and evaluates it according to the test grading specifications for that device.  Various test setup parameters (like test duration, etc.) and grading parameters (such as max and min pulse widths/periods, etc.) can be adjusted by the user through a password protected “Engineering Parameters” interface.  This allows flexibility to perform stricter or more lenient tests of devices to accommodate changing test specifications.

After the data acquired during a test has been analyzed and graded according to the specified parameters, the final results of the most recent test are displayed on the monitor of the test station and are logged to a summary report file.  This file is given a descriptive name to link it to the time the test was performed and the serial number (or other unique identifier) of the device that was tested.   The report file is generated in a PDF format to allow for easy subsequent printing of these results. 

The Visual and Audible Alarm Synchronization Tester also supports the ability to verify its measurement of input signals against a known, calibrated, trusted reference instrument in order to validate the measurement capabilities of the test system.

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The 3D Kinect camera tracks full wire frame skeletons of visitors’ bodies, allowing them to interact with the system with natural gestures and movements. This provides an intuitive and enjoyable control method, which engages users while teaching them more about products and features that the company offers.

The multimedia display was created in .Net 4.0 using Visual Studio 2010 and the Microsoft XNA Game Studio. A 3-D world was created to mirror the physical display case and to provide natural feedback and navigation. When users select an item to learn more about, the .Net application is able to present a variety of customizable images, text, and video information.

This display exhibit uses many cutting edge technologies to create an interactive system that engages visitors in an informative presentation. By leveraging the available technologies DMC was able to create an appealing, engaging tool to feature products and information about the company.

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The solution is also scalable – the Client had an immediate need for short term field testing, which was achieved with a laptop-based DAQ system. Longer term, the system can easily be scaled up to a semi-permanent real-time monitoring and logging system capable of collecting continuous and event-based data over long periods of time.

Learn more about DMC’s LabVIEW programming services.

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