Scantime Increases Company Production by 25%
Our troubleshooting abilities were called upon to analyse a production process for a Durham-based company. The production line was suffering from problems in producing a particularly difficult product to work with, which in-turn increased production downtime making the line extremely inefficient. After studying the production line in operation over several days and looking closely at the production equipment, sensors and wiring etc., we then turned our focus to the Allen Bradley ControlLogix PLC and its PLC program responsible for the control of all this equipment.
After another several days of program analysis, we detected a small glitch in the program operation that lasted only a few milliseconds, could this be the cause the problems? After further program analysis digging deep into the program and equipment signalling, our engineers traced the problem and diagnosed it as a PLC program design error, which has probably been lurking in the backgound for several years, possibly since its original design and installation, making itself apparent when this product was introduced.
Over the next week, our engineers introduced modofications to the existing PLC program and solutions were implemented to help fix this problem, upon Download, the results were instantaneously noticed, line equipment began to work the way it was intended, no more stoppages and the line production increased by a dramatic 25%, the feedback from the company Engineering Manager was; "You would never believe what a difference this has made to production.".
Company investment into Scantime has returned them dividends and annual turnover is set to increase.
About Scantime Automation
At Scantime, we aren't just PLC and SCADA Programming trainers, we are Industrial Control Designers with over 45 years of experience, using Programmable Logic Controllers (PLCs), HMI and SCADA. We provide our expertise to companies who work in the Offshore Oil & Gas Industries, Aerospace and Automotive Production, Food & Drink Processing, Battery and Electronic Manufacture, Pharmaceutical Development, Airport Power Generation and other key industries, worldwide.
Previous PLC & SCADA/HMI Automation Design Services include, High Pressure & Flushing Control Systems for both the Oil & Gas and Aviation Industries, Control and Monitoring Systems for Offshore Oil Rigs, International Airport 24MW Power Generation, Electronic Component Manufacture, Paper Production and Maritime projects.
We also provide Disaster Recovery Solutions for companies where production processes have failed and stopped all production.
If you have process control problems, or need additional resources to meet a deadline in PLC/HMI/SCADA Design, contact a member of staff today.
Recent Case Studies
Below are a few of our recently installed and commissioned automation projects:
PRESSURE & FLUSHING AVIATION PANEL TEST SYSTEM
Using the Siemens S7-1200 PLC and WinCC SCADA package, we designed, installed and commissioned a PLC/SCADA Program for a system that pressurizes various Aviation Panels from 1100 PSI (76 Bar) to 5650 PSI (390 Bar) to test the integrity of the Aviation Panel build.
During a pressure test, the PLC controls and monitors the states of several pieces of equipment including, pumps, valves, pressure transducers and a flow meter to Purge, Increase Pressure at a rate of 100 Bar/Min, Stabilize, Hold and Monitor a pressure drop of up to 5% within the pipework of each Aviation Panel.
The Aviation Panels then undergoes a Flushing process which is controlled via a Drop-In Flushing Rig which uses an electrically driven pump that produces 40 litres per minute during the Flushing sequence. This Drop-In Flushing Rig is controlled from the same Siemens S7-1200 PLC which is controlling the Main Rig.
During this Flushing process, the PLC monitors the cleanliness level of the pipework within the Aviation Panels via an ICM (Inline Contamination Meter) Unit connected to the PLC via RS485 to ensure that all pipework within the Aviation Panels is flushed to the correct AS4059 cleanliness standard.
PRESSURE & FLUSHING OIL WELLHEAD TEST SYSTEM
Using the Mitsubishi Fx3U PLC and Adroit MAPS SCADA package, we designed, installed and commissioned a PLC/SCADA Program for a system that pressurizes Subsea Wellheads from 5000 PSI (345 Bar) to 23200 PSI (1600 Bar) to test the integrity of the Subsea Wellhead during its servicing period.
Similar to our Pressure & Flushing Aviation Panel Test System, the PLC controls and monitors the pressure and how it is delivered to the Subsea Wellhead.
The Subsea Wellheads also undergoes a similar Flushing Process as before where the PLC monitors the cleanliness level, this time from a PAMAS Inline Particle Counter via a 4mA-20mA signal which is sent to an Analogue to Digital Card on the PLC to ensure that the Subsea Wellhead is cleaned to SAE AS4059, NAS 1638 and ISO 4406 cleanliness standards.
HEAT INDUCTION MACHINE
Using the Omron CPM2A PLC, we designed, installed and commissioned a PLC Program for a system that solders Fuse elements to a Fuse barrel by the means of Induction Heating.
Elements are inserted into a Fuse barrel on the top of a solder ring, by the use of a guide, the barrel is lifted by an air cylinder into an induction coil, which melts the solder, this air cylinder is then retracted and the barrel is removed.
The Operator turns over the barrel and manually places a second solder ring onto the opposite end and repeats the cycle with a second air cylinder.
Within this system, the PLC works alongside an Operator, and due to this, several safety systems have to be implement onto the system including 2 SICK Safety Light Curtains which are placed on each table to the left and right side of their corresponding work station.
The PLC continuously monitors the signals given from the SICK circuit and any detected Light Curtain interruption then generates an alarm and places the program into a safe state.
Using the Mitsubishi Fx2N, Fx3U and Beijer E Series HMI package, we designed, installed and commissioned PLC/HMI programs for several machines that create Coils to various lengths specified by an Operator.
The PLCs controls various pieces of equipment including, Mandrels, Motors via Servos, Cylinders, Clamps and Anvils to create these Coils over several stages of an automatic operation which can also be indexed through these stages manually for finer control.