By leveraging Rockwell’s PlantPAx libraries and tools like Application Code Manager, DMC was able to meet the client’s aggressive commissioning timeline while also keeping the project on budget, demonstrating DMC’s core values of “Share Information” and “Make Things Happen.” 

Learn more about DMC’s Rockwell Programming expertise and contact us with any inquires.

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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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Achieving such precision required PID control of the furnace. PID control describes the continuous adjustment and output variation to accurately control a process and mitigate deviation. In this case, PID control would increase the temperature in a specific location in the furnace from 2500°C to exactly 2600°C—not from 2500°C to 2700°C to 2600°C.

DMC implemented a vision system using a specialized camera that can withstand extremely high heats to monitor production. The camera recorded images at a user-specified time interval, communicated with a PLC, and then adjustments were made accordingly. Therefore, the client still maintains some manual control of the process, but it does not require around-the-clock monitoring by an employee.

The production of these crystals is lengthy, requires extreme precision, and constant monitoring. DMC developed a specialized vision system to automate this process, helping our client cut down on costs while maintaining quality standards. The client can also adjust the parameters of the system as needed, so this solution is long term and sustainable.

Read more about DMC’s Test and Measurement expertise and contact us to get started on your next project.

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DMC programmed a Siemens 1500 PLC using the “Optional Hardware Configuration” feature discussed in this blog. This allowed users to reconfigure the PROFINET IO network according to a predefined topology. As new ET200 racks were added to the network, the PLC would automatically assign PROFINET names, IP Addresses, and IO configuration.

DMC also leveraged the full feature set of WinCC Advanced in order to expose all relevant process information to the operators. This included a status log that contained all batch events, a custom text log for each material, an alarm log for delivery faults, and data trending to graphically show hopper weights over the past several days. This data could be both viewed on the touch panel HMI screen and exported for further analysis.

DMC upgraded the client’s SCADA program, developed with WinCC 7, to interface with the new delivery system. Operators are now able to view unit status and delivery quantities through an industrial PC and can initiate material delivery as part of a larger batch.

Learn more about DMC’s PLC Programming and HMI Programming services.

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We then made a protocol gateway that communicated the relevant information from the MQTT service to the correct location in the cloud through an Azure IoT Hub. The MQTT messages were received in the cloud by the broker service, which parsed the data through the gateway for storage in to our SQL cloud database. The gateway is also capable of receiving commands from the website via the API and passing the commands to the PLC.

Finally, DMC built a custom REACT webpage with all the same functionality as the system’s HMI screen on site, as well as a few additional features. The webpage provides a complete user experience with all controls and functionality for the PLC. The website includes access to user administration, additional units of measurement, and the ability to see historical data including flow rates, pressures, alarm logs, setpoints, and usage. The webpage interacts with the API to send and receive data from the cloud database.

DMC also created a mobile version of the application.

Additional Information

DMC trained the client on emerging technologies that are available and guided them toward a more high-tech yet cost effective solution. Additionally, we trained the client on using the custom REACT website we built, the capabilities of the technologies used, and on debugging and troubleshooting.

The customer was also working with multiple other vendors and clients, and DMC navigated communication challenges to manage and complete the project. Finally, we accommodated scope changes and completed additional programming to add features relevant to the client.

Learn more about DMC’s PLC Programming Services and Application Development expertise. 

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Client’s End Product

The client engaged DMC to specify similar modern control hardware and develop changeover plans to minimize downtime during commissioning.  DMC worked with Allen-Bradley distributors and the client’s electrical contractor to determine which control parts had a direct upgrade and which electrical components would be best re-wired for future maintainability.

DMC utilized Allen-Bradley’s PLC-5 to ControlLogix software migration tool to create functionally equivalent PLC programming for the ControlLogix platform.  Since this customer had little controls documentation available to them, DMC worked with the customer to verify expected functionality and to specifically verify high-risk portions of the code such as interlocks that could cause equipment damage or product mixing if not working correctly. 

DMC also migrated the tag and communication paths of the client’s Wonderware InTouch system and reconfigured the HMI system, a terminal server-client layout utilizing ACP ThinManager.

During commissioning, DMC worked with the client’s contractors directly to check out and troubleshoot new hardware. DMC’s engineers provided support to the client’s operations and process engineering teams to start up equipment and implement adjustments during production.  DMC developed a close relationship with the customer and provided a high-level control system understanding to identify and improve portions of the original code function. 

DMC provides ongoing support and training for the client personnel on an as-requested basis.

Learn more about our PLC Programming Services. 

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DMC consulted on optimizing control functionality, user interaction, and features by demonstrating the software to the client’s team during development. This iterative phase helped the client gain confidence in the functionality of the new software and reduced the amount of time needed for on-site commissioning. DMC also assisted the customer in optimizing the functionality of sensitive electrical components by providing remote support and data analysis as the process was brought into production.

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DMC designed and developed a system to perform this automation in a hazardous location. The HMI program guides the operator through a sequence of steps to connect a tank to the system. The system contains a scale and weight and pressure-based valuations that estimate the level of Acetone remaining and the amount needed. After measurement and refilling is complete, the system gives the operator instructions for disconnecting the tank and resetting the sequence.

DMC provided thorough documentation for both sequence-based and operator-based interactions as well as for different tank types.

Due to the facility’s explosive gases, hazardous rated hardware devices were used on the system. DMC designed and implemented a control panel with Z Purge to inject an inert gas into the electrical control panel to ensure safe operation.

Learn more about DMC’s Oil and Gas engineering services.

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Database

The database serves as a central repository for all label configuration data. It is a Microsoft SQL database stored in an on-premise server to ensure continuous stable connectivity from the desktop application and web application. The database schema was designed to support change tracking, so the edit history of any given label can be retrieved and viewed. In additional to label data, the database stores records of all batch printing jobs initiated by the desktop application.

Desktop Application

The desktop application allows operators to manage and initiate batch label print jobs. Users log in to the application with the same Active Directory credentials they use to log in elsewhere in the company network; once the credentials are verified, the application checks the database to determine if the user has access to the application.

Use of the application centers around the management of new print jobs. Users can switch between existing print jobs and add new ones by using the tabbed interface along the left side of the screen. Users may also view a summary screen showing detailed information on all active print jobs.

Creating a print job follows a simple and straightforward process. Users first enter a material number located on the bill of work for the print job they will be initiating. The application retrieves all label artworks associated with that material number and places them into a dropdown for the user to select from. Once an artwork is selected, read-only information pulled from the database is displayed on the right side of the screen so the user may verify they have selected the correct label artwork to print.

Additionally, a list of variable data parameters that need to be filled in for the selected artwork appear. The user must provide data for all of these parameters. Indicators next to each field let the user know what sort of data needs to be supplied for each parameter (e.g. the Expiration Date parameter requires a future date) and whether or not the entered data is valid. Once all data has been entered correctly, the user may generate a print preview to verify the label is formatted correctly.

The final step is to select a printer. This brings up status information about the selected printer (such as whether it is idle, currently printing, in an error state, etc.) and allows the user to bring up the print preferences dialog to configure any printer settings. The user is also allowed to print sample labels as a final check to make sure everything is correct. Once the user is ready, they fill in the number of labels to print and initiate the job. All fields and dropdowns are locked until the print job completes or is manually stopped. 

Web Application

The web application serves as a front-end to the database, allowing for the creation, modification, and management of labels. This includes managing the label stock that labels are printed on, the artwork defining what the labels look like, and the products that the labels are for.

The web application automatically grabs a user’s Active Directory credentials to log them in. The actions a user can take as well as the portions of the web application they can see are tied to their permissions. By default, users can only view label data. Users with administrative privileges can grant additional permissions to any user, expanding their list of capabilities to modifying label data, approving label changes, and uses the desktop application to print labels.

When a record is changed, it moves from an “Approved” state to a “Pending” state. No more changes to that record can occur until a user with approval permissions either approves or rejects the changes. Until that happens, the desktop application uses the latest approved data for any print jobs that are initiated. To facilitate the approval process, users can view a side-by-side comparison of what changed in a “Delta V Report”.

Since some users may wish to request a change without having the permission to do so, a “Change Request Form” can be accessed for any given record. This lists out all the data tied to a record with a second column where the user may type in their desired changes. They can then save or print a printer-friendly version of the form.

To make creating brand new records easier, a “Copy From” feature allows users to begin creating a new record with another record’s data as a template.

Viewing the potentially large quantities of records is simple with the ability to quickly sort and filter grids on any column.

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Learn more about DMC’s MES service offerings. 

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