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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:

  1. Lack of technical staff.  Companies simply not having the staff required to do the job.
  2. Limited Time.  
  3. 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:

  1. New installations.    
  2. Retrofits.  
  3. Expanding or upgrading an existing system.  
  4. 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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