DMC stepped in and enabled its priority pipeline to funnel engineers from across the company and country to quickly analyze, document, and diagnose existing temperature control code. The first step the engineering team took was to create a list of opportunities for codebase improvement for the client to review. These improvements were focused on time to deployment, with an emphasis on system architecture preservation and minimum disturbance to ongoing production tests.

DMC delivered a solution that addressed fundamental issues in thermocouple reading and furnace PID control calculations as well as parallelization and independence of test fixture control. PID control was redeveloped for faster cycle times and smoother temperature trajectories. By solving these issues, temperature control accuracy was improved by 2000%, from an average swing of 60 degrees to 3 degrees over a 24-hour period. By implementing a custom PID gain scheduling algorithm developed by our certified LabVIEW developers in tandem with NI PID control VIs, DMC was able to decrease the unit test time by 1500% without negative consequences to test subjects. We were also able to supply the client with critical operating system updates for their legacy hardware.

Engineers traveled to the client site to aid in tuning, testing, validation, and deployment of the upgraded codebase. After validating the improved control, DMC empowered the client to perform system upgrades independently with rapid deployment tools and detailed documentation. This allowed the client’s engineering team to regain familiarity and confidence in the production system while spending less of their budget on external engineering hours. Within two weeks of upgrade validation, the client had recommissioned all 100 test frames at their site successfully.

Learn more about DMC’s LabVIEW FPGA & Real Time expertise and contact us 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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System Requirements Overview

• Data acquisition autonomy
• Data store-and-forward
• Hundreds of IO channels per test cart
• Thermocouple channels
• Digital channels for sprinkler control
• Various analog channels for flow meters, pressure transducers, humidity, etc.
• Data processing
• Upload data to network destination

Hardware

DMC used UEI’s PowerDNA Cube platform to ensure maximum uptime and reliability. The UEI hardware platform is mechanically and electrically ruggedized for operation in harsh conditions and can be configured with a variety of different I/O channels.

Software

Data Acquisition

DMC developed a C++ application (using the Poco framework and ZeroMQ) that runs directly on the Cube’s operating system. The Cube is configured to run a standard Linux kernel with a real-time API, so all development can be done using the familiar GNU toolchain. This application acquires and processes data during a test, and then sends that data to a network location for analysis and long-term storage.

For accurate thermocouple temperature measurements, DMC implemented cold junction compensation (CJC) calculations in the UEI Cube software per the client’s standards.

The data acquisition stations were synchronized using the Precision Time Protocol (PTP) to ensure that data from all stations could be time-aligned and correlated for post-processing.

Data Processing

Acquired data is streamed in real-time to a centralized server using ZeroMQ. There, data streams are processed based on the test’s custom configuration, offering dozens of preset or customizable formulas (e.g., min, max, integral, derivative, mass flow calculations, heat release rate) selected to meet the client’s requirements for that burn test.

Data Storage

To ensure that no valuable test data is lost if the network location is unavailable, data is cached locally in a Sqlite database until it can be uploaded to permanent storage in a SQL Server Columnstore.

Web Application

DMC developed an ASP.NET Core web backend and a React frontend for operators, engineers, and managers to interact with the test station configurations and historical data.

Some notable features of this application include:

• Multiple levels of user authentication to restrict different user types from accessing configuration screens or running and controlling tests.
• Test configuration, including:
  • Customizing data channels
  • Parameterizing calculations using data channels
  • Attaching point-in-time metadata of associated test
• Multiple options for customizable visuals, including:
  • Types: table, time chart, heat map, x-y plot
  • Selectable time ranges, zoom/pan functions for easy data navigation
  • Ability to visualize full-frequency or downsampled dataset
• Support for importing and visualizing legacy test data

Conclusion

DMC’s use of Commercial-Off-The-Shelf (COTS) hardware paired with several layers of custom software integration provided our client with a robust, flexible, and scalable system to meet their testing needs. DMC continues to work with this client to add new features to the system.

Learn more about DMC’s Test and Measurement Automation expertise and contact us for your next project.

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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.

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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 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 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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For this project, DMC automated the client’s previously manual testing process. This increased efficiency while maintaining quality, as automated testing is faster and less error-prone. With our extensive experience in automated battery testing, we were qualified to follow the client’s step-by-step process and create a tester tailored to their needs.

Functional Specification

The test stand comprises a high-performing NI 4065 Digital Multi Meter (DMM), an NI RMX-4101 programmable power supply, and a Hioki ST5520 Hipot meter for measurement instrumentation. This test suite makes a wide range of testing options available to the client. A Pickering Switch Matrix and a Pickering High Voltage Multiplexer provide a robust switching infrastructure to allow additional instrumentation to be added or new test configurations to be defined depending on future product requirements.

Switch Matrix

The core of the test system is built around a Pickering switch matrix which allows many connections between Device Under Test (DUT) signal lines and instrumentation. This is the heart of the test system’s ability to adapt to changing product requirements.

Not only does the switch matrix allow the test stand to reconfigure a test setup in real-time, it also allows for the addition of instrumentation or DUT signals in the future with minimal changes to hardware or software.

Digital Multi Meter (DMM)

The DMM, in combination with the Pickering switch matrix, allows the test stand to make differential voltage measurements between any two DUT signals or single-ended measurements referenced to ground or the common line of the programmable power supply.

Programmable Power Supply

The PDU provided the power to the Battery Management System (BMS). The Programmable Power Supply (PPS) allows the test stand to apply a wide range of voltages or voltage profiles to the DUT, allowing the PDU to be tested under a wide variety of operating conditions.

The Hipot meter allows the test stand to perform Hipot testing on the DUT. In this case, the Hipot meter was combined with the Pickering high power 12 bank 2:1 multiplexer to provide high voltage isolation for up to 12 DUT lines.

Stand Form

All of this measurement and switching hardware is contained in a compact rollable test cart. This test cart provides the operator interface along with the interface for the DUT.

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Preparatory Phase

DMC started the preparatory phase with a Failure Modes and Effects Analysis (FMEA) to effectively determine which failures can lead to unsafe conditions. These hazards were then evaluated to determine their severity and probability. Finally, our team created risk mitigation plans for each hazard to ensure that all had a low-risk rating. These plans detailed what was required for each hazard: such as redundant series outputs and/or elevated software coding standards to reduce the risk.

Hardware Design

Then, we leveraged our extensive hardware design experience to design a PCB that conformed to our mitigation plans—minimizing the need to adhere to onerous IEC-60730-1 Class C software standards. The Class C standards have significantly more requirements for the code and when validating that the processor is operating correctly—which would have made our solution far more difficult to implement. 

We designed our hardware to allow inexpensive, off-the-shelf processors to be used in conjunction with vendor-supplied IEC-60730-1 Class B safety libraries. This significantly reduced the per-unit cost of the PCB without sacrificing quality. Furthermore, it allowed us to expedite the software development process and deliver a reliable product in a tight timeline.

Software Design

Once we created the hardware, our team designed the software. We used the IEC-60730 recommended V-shaped software design, implementation, and testing framework. This ensured that software modules were broken down from high-level architecture to low-level implementation and test validation requirements were defined upfront. When the programming was completed, each module was validated and tested according to the initial requirements to ensure reliable functionality. This process continued all the way back up the software’s V-shaped design until the entire system was validated.

DMC utilized our vast embedded software experience to design a modern and robust solution for building and unit testing each system. We used Docker to coordinate software tools between our entire team, CMake to control the build, and Ceedling to automate the unit testing of each submodule. This ensures that every build, release, and testing is functional, validated, and does not have unintended consequences. 

Learn more about DMC’s product development expertise and contact us to get started on your next project.

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Once testing begins, the current measurements are displayed on the UI in real-time, processing the fan’s RPM and displaying its fundamental frequency and amplitude. The frequency was determined by using a tachometer. Two triaxial accelerometers placed on the fan were sampled for acceleration data and processed through a Hanning window after the DC frequency component was eliminated. The data was then analyzed in a Fast Fourier Transform (FFT), which allowed us to determine the actual vibration characteristics of the fan.

After the test completes, DMC’s application determines if the test passes or fails, posts the data and results to a SQL database, and communicates through Modbus to let the HMI and the operator know the next test is ready to start.

Learn more about DMC’s Test and Measurement solutions. 

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