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Factory Automation / Systems
Integration
What is a Systems
Integrator?
A Systems Integrator (SI) is someone that provides total
automation solutions for their customers. The
solution usually involves integrating computer hardware and
software, and mechanical equipment. Thus the name
"Integrator".
A Systems Integrator is essentially a general contractor.
We schedule and manage all of the tasks required to
complete a project, including any subcontractors
required.
Why Use a Systems
Integrator
Systems Integrators are employed for a number of
reasons:
- Lack of technical staff. Companies simply not
having the staff required to do the job.
- Limited Time.
- Behind the technological curve. Not able to
keep up with the rapid advances in technology.
Types of Projects
There are four types of projects we do:
- New installations.
- Retrofits.
- Expanding or upgrading an existing system.
- Existing system service.
Capabilities
- Seamless Integration of PLC/HMI systems over LAN/WAN
clients and servers.
- Real-time process data collection
- System architecture design
- Machine design
- Process control and monitoring
- Quality control and monitoring
- Material handling
- Operator interfaces
- Motion control, servo programming
- Remote monitoring and control
- Recipe and batch control
- Historical trending
- Communications
- Redundant systems
- Alarm notification and logging
- Installation
- Startup
- Test & debug
- Documentation
- Training
Experience
Tools we have used:
- Programmable Logic Controllers - Opto22, Omron,
Allen-Bradley, Modicon, Idec.
- Robotics, pick and place, pneumatic
- Computers, Networks, Servers
- Bar code
- Radio Frequency (RF) Tags
- All manner of I/O devices including devicenet
- Databases
Industries
We have experience in a wide variety of industrial and
laboratory settings
We are experts in systems integration. You are an
expert in your process. We rely on you for expertise
in your process (although we are racking up experience in
some amazingly different applications), you rely on us for
expertise in automation systems.
We have worked in the following areas:
- Pharmaceutical and Laboratories
- Food & Beverage
- Pulp and Paper
- Marine
- Aerospace
- Machining and Fabrication
Sample integration
& automation projects:
Wet Lab
PID Control and Monitoring System
Radome Test
Fixture Automated System
PROD
Seafloor Core Sampling Drill Unit
Programming
Coffee
Roaster Automation and Remote Roast
Reporting
Wet Lab Control and Monitoring
System:
The Client:
This client develops vaccines for
fish. The wet lab serves both as a fish hatchery, and as a
challenge area where the efficacy of a vaccine is proven
against a particular pathogen.
The Task:
Provide the client with design,
programming, and documentation for a monitoring and control
system.
System
Description:
The Control and monitoring system
controls such things as water temperature, oxygen
concentration, water filter flush routines, and chlorination
of effluent. In addition, extensive alarming with paging is
provided, as well as complete data logging. Monitored data
include temperature, flowrate, pressure, dissolved oxygen,
effluent chlorine concentration, differential pressure
across filter beds, PID control performance, etc. The
operator has full authority over all control and alarm
setpoints, including all PID tuning parameters.
Controller:
Opto22 G4LC32SX connected to two
HMI's (Human Machine Interface) via Arcnet. HMI's are
runtime app's created in the OptoDisplay component of
Factory Floor, and run under Win95.
Click below for more
info.
Challenge
row PID loop temperature control
Carbon
filter backflush control
Effluent
chlorination control
Radome Test Fixture Automated
System:
The Client:
This client builds composite parts
for the aerospace industry. The test fixture performs a
quality check on the dielectric properties of aircraft
radomes prior to completion.
The Task:
Provide the client with system
design, programming, and documentation.
System
Description:
The automated test fixture is set
up at a radar range on the clients property. It rotates the
test article through a series of pre-set postions in the
horizontal and vertical axis. Antenna and turret rotate in
opposite and equal directions in order to keep the
transmitter pointed at the receiver. Radar signal
attenuation by the radome is recorded at each position
relative to the un-attenuated signal strength. 1/4 wave
shift readings are also taken. This data is logged and
transferred automatically to an Excel spreadsheet template
which is then saved as the final report.
Controller:
Opto22 ISA controller connected to
an HMI (Human Machine Interface) via the ISA bus. HMI is a
runtime app. created in the OptoDisplay component of Factory
Floor, and runs under Win95. The controller directs servo
motors to position the test article. Manual control and
calibration is also available from the HMI.
Click below for more
info.
System
schematic
Servo
control screen
PROD Seafloor Core Sampling
Drill Unit Programming
The Client:
This client provides sea floor
mapping services using towed sonar arrays. They also have
participated in the design and construction of sea floor
core sampling drill units. This project involved the design
and construction of the latest such unit.
The Task:
Provide the client with automation
programming assistance.
System
Description:
Looking something like a mars
lander, the drill unit is lowered by cable to the see floor.
It is equipped with thrusters, lights and cameras for
manuevering. The operator sits on board ship and has remote
control of all functions of the drill unit. All motion is
hydraulic. The hydraulic power units and all I/O are
contained within cylindrical canisters mounted on the drill
unit. Power is routed down the cable. The controller directs
all of the drilling sequences which can be done manually or
automatically. Heading is maintained by a PID loop. Input
fault overides and sensor calibration are also available
from the HMI.
Controller:
Opto22 M4 controller connected to
an HMI (Human Machine Interface) via arcnet. The HMI is a
runtime app. created in the OptoDisplay component of Factory
Floor, and runs under Windows NT. Two monitors are
used.
Click below for more
info.
Drill
unit schematic
Landing
and leveling control screen
Utilities
screen
Coffee Roaster Automation and
Remote Roast Reporting
The Client:
This client provides specialty
coffees to the wholesale and retail markets. They
manufacture a coffee roaster that is available to customers
for roasting their product on-site.
The Task:
Provide the client with design,
automation and systems integration assistance. Create a PLC
program that runs the roaster, stores roast information, and
transmits it's roast history via automated dial-out to a
waiting MS Access appliction each day. Track inventory at
each store in the Access app. Documentation.
Training.
System
Description:
A gas fired roaster that roasts
beans in large batches. Operator selects bean recipe from
touch screen and follows prompts to complete each roast.
Scale weighs each batch to insure correct roast weight prior
to starting. Automated movement of beans from scale to
hopper and roast chamber.
Controller:
Omron C200HX controller connected
to a touchscreen operator interface.
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