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The project snapshots in this section are categorized by industry to
provide an overview of our industry-related experience and
knowledge. These brief summaries are offered as evidence of our
wide range of control system experience spanning many industries.
provide an overview of our industry-related experience and
knowledge. These brief summaries are offered as evidence of our
wide range of control system experience spanning many industries.
PAPER CONVERTING (CORRUGATED)
AUTOMOTIVE
The following Flexo/Folder/Gluers were upgraded with all new controls featuring a PLC-based
system with a color touchscreen as the central operator interface:
The first three machines used a main A-B SLC PLC and remote Flex I/O in each section with a
central 10” color Panelview touchscreen for operator setup and status feedback. The Marten
machine featured a Koyo 200-Series PLC with a 8” color touchscreen from AVG as the central
operator interface.
All included an intuitive job entry procedure for the next box to be run with Auto Setup capability.
Three of the systems were purchased by companies for facilities in Mexico and had the
additional features of one-button switchable inch/metric and English/Spanish language
functionality.
Finally, a diagnostic package was integrated into the system to provide operators and
maintenance personnel with information concerning certain mechanical or electrical problems
in the machine or controls.
In another case, Global Equipment contracted NEU-TECH SYSTEMS for a new, improved control
design for their family of GT-Series Gluer/Tapers.
This design featured encoders on the transport rolls and on the tape head for the ease of job
setup as well as for superior control of the glue and tape placement on the box.
The central element of the control system was a PLC with a 6” color touchscreen as the operator
interface. The system functionality included a wide speed range to handle a multitude of
configurations and an easy-to-use glue/tape setup procedure. In addition, Job Memory
capability was programmed so that repeat orders could be easily recalled for even quicker job
setup.
Two versions were developed for the GT equipment. The initial design featured a Koyo PLC with
Danfoss VFDs. The subsequent design used an A-B Micrologix 1500 PLC and PowerFlex VFDs.
Other projects include:
system with a color touchscreen as the central operator interface:
- Langston Model 253 … 2-Color with a Dual Shaft Slotter
- Koppers G50 … 4-Color with an Integral Die Cutter Section
- S&S ZLQ … 3-Color with an Integral Die Cutter Section
- Mini-Marten Model 616 … 3-Color
The first three machines used a main A-B SLC PLC and remote Flex I/O in each section with a
central 10” color Panelview touchscreen for operator setup and status feedback. The Marten
machine featured a Koyo 200-Series PLC with a 8” color touchscreen from AVG as the central
operator interface.
All included an intuitive job entry procedure for the next box to be run with Auto Setup capability.
Three of the systems were purchased by companies for facilities in Mexico and had the
additional features of one-button switchable inch/metric and English/Spanish language
functionality.
Finally, a diagnostic package was integrated into the system to provide operators and
maintenance personnel with information concerning certain mechanical or electrical problems
in the machine or controls.
In another case, Global Equipment contracted NEU-TECH SYSTEMS for a new, improved control
design for their family of GT-Series Gluer/Tapers.
This design featured encoders on the transport rolls and on the tape head for the ease of job
setup as well as for superior control of the glue and tape placement on the box.
The central element of the control system was a PLC with a 6” color touchscreen as the operator
interface. The system functionality included a wide speed range to handle a multitude of
configurations and an easy-to-use glue/tape setup procedure. In addition, Job Memory
capability was programmed so that repeat orders could be easily recalled for even quicker job
setup.
Two versions were developed for the GT equipment. The initial design featured a Koyo PLC with
Danfoss VFDs. The subsequent design used an A-B Micrologix 1500 PLC and PowerFlex VFDs.
Other projects include:
- an upgraded bander control system with pattern selection and conveyor logic for
transport to the appropriate shipping dock. - a networked PLC system for a 3-color Ward die cutter featuring an A-B Panelview
operator interface for register control and stacker setup. - an electronic line shaft system for a set of custom folding rails and stacker interfaced to a
200” flexo.
Portfolio
We designed, programmed and implemented Allen-Bradley PLC systems for several paint
booth applications featuring recipe control for various body types including the ability to purge
paint lines and change colors between jobs as they passed robot stations.
In other projects, we provided design and commissioning services for various PLC-based
“power and free” conveyor control systems to several major automotive assembly facilities.
For a particular assembly plant, we implemented an A-B PLC-based system for a parts and
delivery line to assemble automotive seats in a JIT environment.
booth applications featuring recipe control for various body types including the ability to purge
paint lines and change colors between jobs as they passed robot stations.
In other projects, we provided design and commissioning services for various PLC-based
“power and free” conveyor control systems to several major automotive assembly facilities.
For a particular assembly plant, we implemented an A-B PLC-based system for a parts and
delivery line to assemble automotive seats in a JIT environment.
FOOD/BEVERAGE
We designed, programmed and commissioned a PLC system for high-speed sortation
equipment that received product from (18) production lines and then delivered each product to
its proper warehouse area.
The system used a bar code scanner to identify the product and divert it to the proper conveying
equipment as set up by operations personnel at the operator interface station.
For another food processing company, we implemented a complete, plant-wide SCADA
system featuring A-B PLC5 processors interfaced to SmartPanel operator interface stations
located throughout the facility for recipe control and data collection.
equipment that received product from (18) production lines and then delivered each product to
its proper warehouse area.
The system used a bar code scanner to identify the product and divert it to the proper conveying
equipment as set up by operations personnel at the operator interface station.
For another food processing company, we implemented a complete, plant-wide SCADA
system featuring A-B PLC5 processors interfaced to SmartPanel operator interface stations
located throughout the facility for recipe control and data collection.
HEAVY EQUIPMENT
We commissioned a new engine assembly and testing “power and free” conveyor system for
a major agricultural manufacturer using an Allen-Bradley ControLogix PLC with a MES link for
routing and tracking information.
For a major pump manufacturer, we designed and implemented a control system for an
integrated
parts cleaning and finishing line featuring “RFID tracking” and a TCP operator interface for
“line setup” as well as system diagnostics.
We designed, programmed and commissioned new PLC-based control systems for
grinding, welding and milling locomotive traction motor assemblies for a prominent builder of
railroad power equipment.
a major agricultural manufacturer using an Allen-Bradley ControLogix PLC with a MES link for
routing and tracking information.
For a major pump manufacturer, we designed and implemented a control system for an
integrated
parts cleaning and finishing line featuring “RFID tracking” and a TCP operator interface for
“line setup” as well as system diagnostics.
We designed, programmed and commissioned new PLC-based control systems for
grinding, welding and milling locomotive traction motor assemblies for a prominent builder of
railroad power equipment.
CHEMICAL
We designed and implemented PLC systems for several “blown film” manufacturers. The
systems included the weighing and delivery of the plastic pellets to the extruder, control of the
extruder heater zones and the logic for the rewinders. Operator interface stations were also
configured for production setup and data logging.
For a dry fertilizer manufacturer, we programmed and commissioned a new A-B PLC system
to control the batches of ingredients as they were mixed, dried, packaged and palletized.
systems included the weighing and delivery of the plastic pellets to the extruder, control of the
extruder heater zones and the logic for the rewinders. Operator interface stations were also
configured for production setup and data logging.
For a dry fertilizer manufacturer, we programmed and commissioned a new A-B PLC system
to control the batches of ingredients as they were mixed, dried, packaged and palletized.
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