Application Story Center
Application: DL205 does the dirty work on a dump scow Products used: DL205 PLC Description: We use a DL205 PLC aboard an ocean going split hull dump scow. The vessel was originally controlled with a Mitsubishi FX-48MR-DS PLC. We replaced that controller because it was outdated and the DL205 offered us more flexibility for less money. The DL205 integrates the diesel engine control, hydraulic controls and the telemetry. Radio signals from a tugboat send commands to the scow that start the engine, cause the scow to open and close and to stop the engine. The DL205 has numerous safety interlocks and automatic functions. We have been able to standardize a number of different operations using this same system; thus the number of replacement components is kept to a minimum. Also, we are able to expand equipment control and monitoring very easily with the DL205 series. Submitted by: |
Application: Testing and data collection made simple with DL205 PLC, EZTouch screen and DataWorx software Products used: DL205, EZTouch, Dataworx Description: We were tasked with developing a production final tester for a new line of temperature limit controllers. Based on the requirements, we chose a DL205 base and D2-260 CPU with I/O cards - an analog card controls our temperature sensor simulators and allows for a barcode reader and printer. The operator interface is an EZTouch panel. Once we wrote the main program we just cloned the “recipe” and changed the set point parameters and I/O requirements for each model. (This was quite a programming time-saver and all the operator has to do now is touch one button to change the model being tested.) We are using Dataworx to collect the tested parameters and make the information available to whomever requires it, suc as quality, engineering, or even the customer. Submitted by: |
Application: DL205 with WinPLC used to control and monitor chipfeed system Products used: DL205 and WinPLC with Entivity Studio software Description: Southland Instrument Services installed four each DL205 PLC units using WinPLC with Studio software to control and monitor three chipfeed boilers and the chipfeed system. Think & Do Studio is used for HMI with Ethernet communications. This system has been in service for 2 years trouble free. These PLCs are the most dependable and versatile PLCs Southland Instrument Services has ever installed and maintained. Submitted by: |
Application: D2-260 replaces old controls to keep newspaper press running Products used: D2-260 with Ethernet card, remote units for i/o Description: We ripped out the old controls and installed new DC drives at a newspaper press that includes 9 units, plus a folder. We then installed a "master" D2-260 PLC with Ethernet for communicating with remote I/O in the press units. The drives and PLC communicate with the maintenance computer for troubleshooting locally and remotely. The entire press was retrofitted without the newspaper ever losing one production run. It’s been working great for 6 months now! Customer down time losses went from about a week per month to no losses in 6 months. The system has paid for itself. Submitted by: |
Application: DL205 and EZTouch increases productivity for coil form manufacturer Products used: DL205 & 6" EZTouch Panel Description: Cosmo Corporation produces coil forms for the electrical and electronic industries. This includes thermoplastic and thermoset molding, as well as round wire, square wire, flat terminals, and assemblies. My challenge was to improve the assembly operations. By implementing systems using the DL205 and EZTouch Panels, I was able to build user-friendly controls that include automatic and manual operation, but more importantly, complete diagnostics and data collection at the touch of a button. The new controls and diagnostics reduced maintenance requirements to the barest minimum, and the data collection provides production with accurate, real-time operator, part number, and machine capability information. This being a newly implemented project, the full impact of the improvements is yet to be appreciated, however I can say that the reduction in maintenance, increased reliability, and improved performance has improved productivity by nearly 14%, and the production data provides information for accurate/competitive pricing of our products. Submitted by: |
Application: Sports hall uses DL240 and Optimate panels to control lighting system Products used: DL240 and Optimate panels Description: Manchester City Council redeveloped one of their indoor sports halls to incorporate a complex lighting scheme that enabled them to switch the lighting in specific areas depending on the community usage. The main arena was fitted with multiple High Bright Sodium Luminars selected in combination for different uses. Separate balcony and peripheral lighting was also provided. In the event that any of the main arena lights failed while selected, or if the PLC failed or was isolated, it was essential for safety reasons that the emergency lighting be initiated automatically. Control of all the lighting had to be carried out from one of two locations: either the reception area or the director’s office, the first being 150 meters away, and the second 30 meters away from the main PLC control system. We used a DL250 with two Optimate pushbutton panels networked with another Optimate panel to start or stop any sequence of lighting from either location, and also to inform both offices simultaneously which selection had been made. Submitted by: |
Application: Aging pen-chart recorders get a boost from DL205 PLCs and DataWorx PLC Professional Products used: DL205, H2-ECOM Ethernet communication module, and DataWorx PLC Professional Description: Our customer manufactures large plastic
parts through moulding or other processes and had several pen chart recorders
in need of replacement. They were used to record whenever a product was
made, and with over 50 machines on the factory floor, it was time-consuming
to read the data when it was produced on paper rolls. Syzygyn Ltd was
asked to propose an alternative solution, which was initially to use DL250
plus DataWorx PLC V1.2, communicating through an H2-ECOM Ethernet module.
We would simply feed the existing field cabling into the PLC, develop
the communications routines and then, presto! We were in! Submitted by: |
Application: DL205 PLC controls plastic sheet cutting Products used: DL205, D2-CTRINT counter interface module with Remote I/O and Optimate panel Description: Our customer manufactures plastic components
from a continuous sheet that is 1 meter wide. Prior to forming the product,
the sheet is heated to a working temperature while passing between two
heater platens. Platens are constructed with a total of 75 x 1 kW ceramic
heaters, with each heater individually controlled and monitored for failure
with current sensors. At a specific distance traveled, which is computed
in the PLC as a function of the Set Length, an impression is made in the
product so that when the Set Length is reached, the sheet is cut by a
motorized blade moving through a defined operation as dictated by the
PLC. The bulk of the inputs take in the current sensor signals, and manipulate
outputs to drive individual alarm lamps whenever a heater fails to register
a switching operation, as determined by temperature controllers. The D2-CTRINT
high-speed counter module is used to measure the sheet speeds at two points,
via shaft encoders, with the stretch value computed and available for
display when selected on the Optimate. The Optimate is used to set all
the machine variables, to confirm the specific alarm as it occurs, to
give secondary indication whenever the cutting mechanism mode is changed,
and to be used as a maintenance tool to determine the sheet speeds at
feed-in and take-off locations and the last 10 alarm messages. Submitted by: |
Application: D2-260 CPU handles bartending duties for beer cooler application Products used: DL250, D2-260 CPU, H2-ECOM, CTRINT, F2-04AD-1 Description: I'm using a DL250 to monitor the 2-tap beer cooler in the bar in my home. My wife and I entertain quite a bit, and we were tired of running out of one of the beers in the middle of a party or on a weekend. So being controls engineer that I am, I added an inline flow meter to both beer taps to measure volumetric flow and I also monitor CO2 pressure on the kegs along with cooler temperature. I have also set up alarms to tell me when the keg levels are getting low, CO2 pressure is out of limits, and cooler temperature is out of limits. The system is currently in place but without any type of HMI. I currently
have to use DirectSOFT software to check on the keg status. I want to
develop a Java application to connect to the ECOM module so that it can
be viewed from the Internet. I also want to install an EZ-Touch on the
bar but have to wait for budget to allow me to spend the money. Submitted by: |
Application: Aluminum anodizing system controlled with help from D2-260 and EZText panel Products used: D2-260, EZText 220P Description: Our system controls aluminum anodizing. The operator uses the EZText panel to enter the size of the job and the desired thickness of anodizing. The D2-260 translates this into the necessary current, voltage, and time profile required to produce the desired result, and controls a 300kW SCR switched power supply that delivers the anodizing current to the workpiece. Since the optimum waveform has both short term (~1sec) and long term (~5min) components, and needs precise control over two orders of magnitude (10A to 1000A), the floating point math capabilities of the D2-260 are used quite heavily. The environment is extremely noisy electrically (because of the 300kW SCR phase angle switching), so the design of the grounding and shielding, as well as software filtering, were very important to the success of the project. In addition to the standard PLC on/off inputs and outputs, analog inputs
and analog outputs are used as part of the monitoring and control process. Submitted by: |
Application: D2-250 CPU bails cotton with help from EZTouch panel Products used: DL-205 PLC, EZTouch operator interface, modem Description: We used a D2-250-1 CPU in conjunction with 3 Remote I/O drops for process control of a cotton baling hydraulic press. The system was able to cut our field wiring costs in half, as well as the installation labor. An EZTouch operator interface performs operator control and provides diagnostic information of the entire control system. An MDM-TEL modem provides the means for troubleshooting over the phone. Submitted by: |
Application: DL205 expansion modules help in assembly of medical humidifiers Products used: DL205 and expansion modules Description: We recently designed and built a $250,000 automated assembly machine that is used to assemble medical humidifiers. We used three Beta test release D2-EM expansion modules, along with two D2-CM expansion base controller modules. As this was a very involved system that was needed in a tight time frame, we had to be able to build major portions of this system simultaneously and independently. Using the expansion capabilities of the DL205, we were able to accomplish this. By using the DL205 in place of an expansion module we could actually perform pre-run testing and debug on one section while other sections were still being developed. This was achieved by temporarily treating each control section as a complete entity using a PLC in each control box until they were ready to be integrated. Submitted by: |
Application: DL250 performs control for positioning system invention Products used: DL250 PLC, Directsoft Software, Relay Output Module, F2-CP128 Coprocessor, EZTouch panel Description: I invented and developed the Automated ShaftAlign Positioning System (U.S.Patent no.5896672). This system can perform an automated vertical and horizontal angular and parallel offset alignment on electric motors weighing up to 10,000 lbs, coupled with industrial rotating machinery, in a matter of minutes within an accepted total tolerance of only .0005". This system comes with its own positioning system that precisely moves the motor to compensate for misalignment measurements. The system consists of measuring devices, control and computing modules, electric powered horizontal and a vertical jacking system. For example, when doing a horizontal alignment, the system simply measures alignment information and displays it on the touchscreen. If an operator press “align”, the rear jack moves until the angular is corrected then automatically stops when finished. If “parallel offset” is pressed, the rear and front jacks move and maintain an .0005" tolerance until the parallel offset is corrected, then stops when finished. Submitted by: |
Application: Hydraulic punch presses stay running with D2-250 CPU Products used: DL205 D2-250 CPU, EZText panel Description: We used a D2-250 CPU and an EZText panel to control the positioning of rotary and slide dies in hydraulic punch presses. Our customer had loss of production from excessive downtime and also had some very costly die repair. We designed and installed a new die monitoring control system and used the EZText panel to allow setup, provide diagnostic messages for faults as they occurred, and to totalize their production. All this will soon be interconnected thru Ethernet to an office in order to view production data. The diagnostics have paid for themselves many times over by enabling the operator or maintenance person to get equipment back on line quickly. The customer plans on installing this system into the remainder of their presses. We have made a loyal friend and a very good customer, thanks to ADC and their products. Submitted by: |
Application: D2-250s PID loops control pumps in residential water system Products used: DL 250, analog I/O Description: We used PID loops in the 250 to control
three pumps and maintain pressure in a residential water system. The flow
demand varies from zero to 250 gallons per minute. The pumps all have
variable speed drives with the speed reference and Run commands coming
from the 250. At low flow, one pump alone runs as needed to maintain the
pressure. As the flow increases, the other pumps are brought on either
in tandem with the first or at a constant flow rate. The flow from each
pump has an upper limit - if the total flow demand exceeds the combined
upper limits, the pressure will fall. The result is that each pump can
operate in an optimum range on its pump curve, and a widely varying flow
can be delivered and the pressure is maintained very closely. Submitted by: |
Application: DL205 automates lab measurement to provide results in minutes Products used: WinPLC module, H2-SERIO, F2-08AD-1, F2-08DA-1, D2-16TD2-2, D2-16ND3-2 Description: DL205 and WINPLC used to create an on-line laboratory robot. The complete unit is used to monitor cyanide in plant process water. It does this by automating the wet chemistry measurement traditional done by lab technicians. Because of the flexiblity of the DL205 and WINPLC almost any laboratory measurement can now be automated and used for process control. Plant engineers now can get lab results in minutes instead of hours, improving quality and lower costs. Submitted by: |
Application: D2-250 CPUs keep the presses going at busy printing press Products used: D2-250 CPUs and Ethernet cards, 10-inch EZTouch panel Description: This system monitors the four main ink lines to a printing press while it’s running. If for any reason the ink pressure falls below 25 pounds, the ink will not print on the material and those pages will be thrown away. We set up one PLC to look at the four pressure sensors with a 4 to 20 ma output, which is input into the analog cards and calibrated. This PLC is located in the compressor room and hooked to the second PLC by Ethernet. The second PLC is located in the “Quiet Room” and it takes the calibrated information and displays it on the 10” panel. The second unit also has the adjustable setpoints, trip points and graph displays to let the press operators know how everything is operating. The system has also been expanded to monitor oil pressure, vacuum pressure, water and air temperatures and also water conductivity, all with different levels of access to the setpoints and calibration through the touch screen. With the printing of 350,000 sections a day, 365 days a year, the panel has become a tool for troubleshooting and maintaining the press. Submitted by: |
Application: Automated bullet assembly machine hits the mark Products used: DL205, EZTouch panel Description: When a leading black powder bullet manufacturer needed to assemble their patented bullet components, they turned to JSL Design. The huge growth that this company was experiencing left them with a large number of employees performing repetitive assembly tasks. JSL proposed a machine consisting of multiple vibratory part feeders, a servo controlled main index/assembly station, and a DL205 PLC-based control system with a EZTouch color operator interface panel for easy operator interface and troubleshooting. All mechanical components were designed in a 3D CAD system, and all electrical design was done in AutoCAD. The machine was thoroughly tested in JSL’s facility before acceptance and delivery. The customer was quite happy to find that the machine produced 140 bullets per minute instead of the expected 120 outlined in the contract. Submitted by: |
Application: DL205-controlled system packages consumer hand tools Products used: DL205, F2-08-AD, and EZ-220P Description: My customer's customer, a maker of consumer hand tools and accessories, wanted faster, yet easier to use machines to package saw blades, drill bits and similar tools. I selected AutomationDirect’s DL205 PLC family for this project, along with an EZ-220 operator interface to allow production engineers to preprogram all machine parameters, or recipes for up to 40 different parts. I also added an Infrared Optical Sensor so the PLC could read the film temperature and index everything when the temperature reached the setpoint for a product stored in the recipe. Controlling the vacuum level that is used to pull the film down to the card was also critical and previously done with a mechanical control. I found that an automotive MAP (manifold absolute pressure) sensor would measure vacuum levels, was inexpensive, required 5V to operate and generated a 1-4V output signal and was perfect for use with the DL205’s analog input module. Simple zero/span calibration settings (again through the operator interface) let the engineer set recipe values directly in inches/hg. To prevent misalignment, I added an array of magnetic proximity sensors beneath the table to detect the hole in the circular saw blades. Absence of the hole (detecting the blade) would stop the die cutter from cutting the card. The customer was ecstatic with the outcome. Besides a machine that anyone could run, production engineers had data they could use to determine productivity. Submitted by: |
Application: PLC-controlled system keeps ground recharge system running in Arizona heat Products used: DL205, DL05, Lookout Direct Description: We were hired to develop a fully automated ground water recharge project in the middle of the Arizona desert, where the summer temperatures are 115 in the shade. We installed a licensed radio network linking 25 DL205s and DL05s to a desktop computer in an onsite office running Lookout Direct. The on site computer has a cellular link back into town. The project has been an overwhelming success. It has allowed the facility to be operated from another state (Nevada). Submitted by: |
Application: DL205 and EZTouch panel run and monitor dye-jacking systems Products used: DL-205, motor controller/protector, EZTouch panel Description: Modern Hydraulics Inc, builds die separators for the automotive and appliance industries. The company’s machines open, level, close, un-jam and test dyes used to form sheet metal. The machines synchronize dye-jacking systems to keep the upper and lower dye shoes parallel and automatically adjusts for dye jack pockets that are not identical in opening height. The system makes use of a DL205 PLC, motor control/protection device and electronic pressure and position sensors to monitor the operation of the machine. An 8" or 10" color EZTouch panel provides specific operating instructions at the appropriate time to the operator. The panel took the place of hydraulic gauges and written instructions, allowing inexperienced personnel to operate the machine safely and productively. The machine can operate either four or six jacks, and the number of jacks to be used is selectable by the operator. “By using AutomationDirect products and superior customer service and technical support, we've been able to thoroughly modernize and increase the capacity of our line of machines, while decreasing costs by eliminating the need for two sizes of machines for differing applications,” says Lance Renshaw. Submitted by: |
Application: DL205 controls climate at Agricultural Research Facility Products used: DL-205 with Ethernet base controllers, Think and Do Software Description: My firm designed and installed a process monitoring system which incorporates 14 DL-205 bases with Ethernet Base Controllers and over 900 points of control. Think&Do software runs on two servers in a dual redundant configuration providing operator interface at this East Texas (Houston area) location. The application is an Agricultural Research Facility, which genetically alters the Rice Plant for enhanced growth in diverse climates. The control system maintains environmental climate conditions in greenhouses and special growth chambers to document the effects of specific mutations of the plant. Submitted by: |
Application: Upgraded machine helps students learn injection molding Products used: DL-205 with D2-240 CPU and EZTouch panel Description: I upgraded a 40-year-old plastic injection-molding machine at Richmond Community College to present day technology standards by installing a DL-205 programmable logic control system that is connected with an EZTouch operator interface. The machine is used in the College’s Injection Molding class. The PLC automates cycle times that affect the opening and closing of molds and the temperature, pressure, and amount of plastic extruded into the molds. The machine mold makes six sifter fitments, which are two-inch round disks with a star-shaped series of holes. The product can be used as part of a shaker-type dispenser for pepper or other finely ground products. Software to program the PLC is installed on computers in a lab and students can program and simulate test runs before downloading the perfected program onto a laptop computer and transferring the program to the PLC for actual machine operation. The color touch screen has 20 pages of interactive information including process parameters, diagnostics, statistical data, and process graphs. The machine has the option of being upgraded to a higher level in the future, which could involve such things as closed loop processing and CIM (computer integrated manufacturing). Submitted by: |
Application: DL-205 controls passenger comfort on private railroad car Products used: DL-205, SJ100 drives, Optimate panels Description: The rebuilding of a private railroad passenger car required the upgrading of the electrical system. Knowing the car representative's desire for proven technology, I approached them with the idea of total car automation using a DL-205 PLC with a 250 CPU, five remote racks, three SJ100 drives, and 20 Optimate panels for crew troubleshooting of car problems and information display for passenger comfort. The 205 controls all heating and air conditioning equipment, and allows for troubleshooting of car equipment. The largest part of the program is the crew/car/passenger interface. Each room has an Optimate panel outside the entrance door to display messages such as "DO NOT DISTURB", "SERVICE REQUEST". etc. Each room also has a panel inside that displays messages from the crew such as "DESTINATION APROACH", "MEAL CALL", and others. The panels also display outside air temperature, speed in MPH, air brake pressures, etc. Submitted by: |
Application: D2-250 maintains water pressure for city water system Products used: D2-250, F2-4AD2DA, D2-08CDR, OP-613 Description: We created a water pressure controller for a local city water system. We used a pressure transducer to feed a water pressure signal into the analog card. The output from the analog card is used to control the speed of a 75hp well pump on a frequency drive to keep the city water system at a more constant pressure. Setpoints are entered with the OP-613 panel and the pressure is displayed as well. The system controls the startup sequence, releasing the well flow to drain and slowly cut into the system to prevent a pressure spike on startup. It also controls the shutdown to prevent a pressure dip. System pressure is maintained with a PID loop in the D2-250 processor. Submitted by: |
| Application: DL205 and Optimate Panel control a speedy filling machine Products Used: DL205 and Optimate Panel
So an Optimate panel was designed into the system to work with the PLC.
If the machine fails in any part of the fill cycle the operator hits a
stop button on the panel at the point of failure, and then replays that
part of the fill cycle over and over to make a better analysis of the
problem. This machine was another AutomationDirect project that went very
well. Submitted by: |
| Application: DL205 system makes batch control easy as pie Products Used: D2-240 PLC, D2-16ND3 input module, D2-12TR output module Description: Our customer is an OEM making bakery weigh batch systems. They use our Unipulse brand F800 batch controller with the AutomationDirect D2-240 PLC, D2-16ND3 input module, and D2-12TR output module. The system handles all weighing functions including parameter storage for the ingredients (e.g. sugar, water, flour, honey). The AutomationDirect PLC performs the sequencing, timers, alarms, etc. This application has been repeated in many food and chemical plants. Submitted by: |
| Application: EZTouch and DL205 control high-speed vacuum pumping Products Used: EZ-Touch 6" color and DL205 Description: We used the DL205 to control a high speed vacuum pumping system that is used at the ChemMatCARS Advanced Photon Source at Argonne National Labs. This system is part of a Small Angle X-Ray Scattering (SAXS) camera that must able to quickly change sample to detector distance. The EZ-Touch panel makes the system very user-friendly, and allows administrative control to only those who should have it. Submitted by: Slide show of pictures of this application: |
Application: DL250 weighs and moves boxes in automatic weigh packing system Products Used: DL250 Description: I used a DL250 and a F2-04AD-2 A-D card to control a completely automatic weigh packing system. This system is the final point of our work cells. The A-D card is coupled to a load cell via an amplifier to do the weighing. Linear cylinders index the empty boxes onto the weigh platform where the box is filled. After filling, the box is moved to an elevator to raise the box to proper work height. Then the box is coded and moved onto a holding conveyor. The system had to be very cost effective to work. I sourced all I could from AutomationDirect to get the best value on electrical and electronic parts. Submitted by: |
| Application: DL205 PLC helps company build automated machines to control steps of shutter production Products Used: DL205, DirectTouch panel Description: G&L Technologies in Alpharetta, GA builds automated machines that complete all of the processes of shutter building, from cutting to final assembly. The company chose AutomationDirect's DL205 as an integral part of their machines. One machine, the LPS-36T, controls louver production. Louvers are the pieces that go across each shutter frame that can be manipulated with a tilt rod to open and close the shutter. The machine uses the DL205 PLC to manage the operation of all electro-mechanical components and communication, including index speed and distance, system stapling, drill and pin sequencing, and parts infeed coordination. An operator interface provides the operator with information such as louver width and machine status. The PLC is programmed so that a range of production parameters is supported on the louver production machine. Therefore, many different manufacturers can take advantage of the automated systems, regardless of the shutter size and style they are manufacturing. The raw louver stock comes in many different lengths and can be produced in various wood types, as well as plastics and composites. The LPS-36T system accommodates raw louver stock lengths between 18 inches and 16 feet and allows the operator to enter louver length, width and thickness using the operator interface panel. "The excellent service we receive from AutomationDirect, along with the ease of programming, flexibility and small size of the DL205, are the reasons we continue to choose this PLC for our machines," says Lance Reed. Submitted by: |
| Application: DL205 trains honeybees to recognize food odors Products Used: DL105, DL205, EZTouch panels Description: An Ohio State University science lab specializes
in the study of the olfactory learning behavior of honeybees. Honeybees
can learn to associate all kinds of odors with food; lab personnel train
them in the same way that Pavlov trained dogs to learn that a ringing
bell meant he would feed them. Submitted by: |
| Application: DL205 gets into the groove with tubing Products Used: DL240, DINnector terminal blocks, DirectSOFT programming software Description: Youngstown Tube Company makes tube and pipe in different lengths with grooved ends. When it was decided to update the old mechanical gear system transfer and single groove heads they had been using for grooving, the engineers opted to use PLC control for every aspect. The new machine arrived without any electrical controls installed. The electrical engineer started from scratch and based everything around the DL240 PLCs and supporting products. Within two months, all the panels were built, wired and in place. It took another week of concrete and wiring and all was done save for the program. Major Lee Back, Sr. says "I knew what I wanted but could the DL240s deliver? Without a doubt. I had them coded and debugged within two days thanks to the easy-to-use software." The resulting DL240 control system almost doubled grooved production. With the smooth transfer of the new pneumatic platform, coupled with the almost hands free grooving and secondary transfer, that part of the plant is no longer the pinch point for producing tubing products and shouldn't be for years to come. "Can't beat the support. Can't beat the simple on-line ordering.
Can't beat the interchangeability. And one thing I've found out that impresses
me most of all...Can't beat the pricing. We are adding a new line within
a year and I doubt it's a secret what I'm going to use for the controls." Submitted by: |
 Application:
DL250 and LookoutDirect control and monitor heatshrink tubing production
process
Products Used: D2-250 PLC , color touch panel, LookoutDirect, F2-CP128 BASIC CoProcessor, F2-THM, thermocouple input module, F2-08AD-1 analog input module, and H2-ECOM Ethernet communications module Description: A D2-250 based PLC connected to a color touch panel is the heart of a stand-alone custom heatshrink tubing processing machine. The D2-250 controls and monitors all digital logic and analog signals. Descriptive process information is shown to the operator via the touch panel. All controls except power and E-Stop originate in the touch panel. The CP128 BASIC CoProcessor has a custom program that communicates with two smart servomotors. It passes speed and operation parameters to the servos and polls the servos for status, torque and position information. The ECOM module is connected to a 10-megabit network and data is collected by Lookout Direct. The data contains all operational parameters for statistical analysis and process data collection. The ECOM module also allows backup of and modification to the D2-250's program effortlessly over the network. Submitted by: |
 Application:
DL250s and DSDataServer perform batch management in textile dyeing facilities
Products Used: DL250 PLC with I/O, H2-ECOM Ethernet Module, DirectTouch HMI and DSDataServer32 (OPC communication) Description: Cubex has developed a Windows based Batch Management System that utilizes the Automation Direct DL250 line of processors. All production data for historical trending, alarm logging, machine control and production/efficiency/cycle reporting is provided through OPC and housed in a Microsoft SQL Server 2000 database. Tools are included for controlling, configuring and scheduling machines, formula management, procedure management, reporting and troubleshooting. The system has recently been installed in four textile dyeing facilities controlling 23 textile dye machines. The flexible system allows the machines to run in either stand-alone or hosted modes, using a DirectTouch touch screen for local machine setup and control. Another application, Process Explorer, uses the same architecture for collecting and reporting process data. Process Explorer is generally geared more for discrete processes such as assembly and packaging. For more information visit Cubex at www.cubexcontrols.com. Submitted by: |
| Application: DL250 makes seed pellets, exchanges data with PC for setup and batch tracking Products Used: DL205 Family with D2-250 CPU, DirectTouch M-320, H2-ECOM, DSData Server
Submitted by: |
| Application: DL250 allows remote control of industrial refrigeration units Products Used: D2-250 CPU, analog inputs, RTD inputs, 120 VAC inputs and outputs, and PanelMate Color Touch Screen Description: An industrial refrigeration firm was looking to upgrade its control package for its clients. They used the D2-250 PLC and wrote a refrigeration program that included enough inputs and outputs for 4 or more refrigeration control groups. RTDs bring in temperatures and analog I/O brings in the 4 - 20 mA signal for the NH3 (Ammonia) sensors. A system of 10 panels on a roof in Kansas is working great since installation over two years ago. The panels are "daisy-chained" with RS485 to an Iconics Genesis HMI in the maintenance rooms. The maintenance people are able to change the temperature settings and defrost settings, and even turn off a valve manually without climbing on the roof on a slick morning when it is 10 degrees outside. They are very happy with the PLCs and the price that they paid. Submitted by: |
| Application: D2-250 cooks up a mean barbecue sauce Products Used: D2-250 CPU, 9-slot base, RTD input, analog and digital I/O, H2-ECOM, DirectTouch color touch panel, DDE Server Description: A Barbecue Processing Line consists of a cooking process, cooling process, packaging system, metal detection, and CIP (Clean in Place) system. Stage programming facilitated the five systems to reside on one PLC using a touch screen operator interface. The goal was to set up a BBQ Sauce Processing Line in a USDA inspected meat plant and produce high quality product with greater consistency and more efficiency. The PID functions of the modestly priced 250 CPU not only precisely control the cook temperatures but the built-in ramp/soak feature made the sophisticated cooking steps like childs play. The Toledo platform scale with analog output card made the packaging process completely automatic and still provided NTAP scale certification. RTD and analog inputs interfaced to a variety of temperature, conductivity, process PH, ultrasonic and hydrostatic level sensors for vessel and tank levels, as well as process parameters required by plant personnel and USDA. With just two inputs and two outputs, the metal detector was automated to reject contaminated product through diverter valves. The system includes 30 valves (sanitary steam and water), five product pumps, four chemical pumps and agitator drives. Ethernet communications networked with a popular SCADA package and the DDE SERVER package documents the entire process, generates reports and stores multiple recipes for different sauce recipes. Submitted by: |
| Application: D2-250 performs all controls for a glass tempering oven Products Used: D2-250 CPU, DP-C320 touch screen, F2-04THM temperature inputs, DC I/O Description: Our customer requested the development of a low cost and easy-to-operate control system for a glass tempering oven. The vertical oven is very compact, with 12 temperature zones (power and monitoring) and two inverters, one for the conveyor, the other for the fan air blower. Using the DP-C320 touch screen, the oven operator has total visibility and the ability to perform the job with minimum manual intervention. Using the touch panel reduced the hardware by eliminating individual control and indication devices. The DP-C320 incorporates all the switches to run the system. It displays the percentage of power for each of the 12 zones, zone temperatures (up to 720 °C), the oven cycle status, up to 50 recipes (for glass types and width), as well as the inverters' speed. This was our second application using the DP320 and the success of this system has allowed us to develop another oven for tempering glass with 36+36 temperature zones for increased production, using the 32-point module types. Submitted by: |
| Application: DL250 PLC and M320 touch screen controls wood fired boilers Products Used: D2-250 CPU, M320 touch panel, DL205 discrete and analog I/O Description: As a part-time consultant, I developed a control system for wood fired boilers based on the D2-250 PLC and the M-320 touchscreen. Standardized code, with options and adjustability configurable via the touchsceen, eliminates the need for a programming device for the startup technicians. The flexible I/O configuration of the DL250 allows users to invoke features that require alternate rack module configurations from the touch screen, followed by a powerup. (Try doing that with an A-B SLC500). Several of the internal PID loops perform control, and the internal floating point math allowed for the development of more complex algorithms. The M-320 touchscreen is very powerful, which makes the system user-friendly for operators that haven't had much experience with process controls. In addition to trend graphs, an alarm log, and pages with setup parameters, I included "slot monitor" pages that allow the user to view the status of every I/O point. These have a password activated "force" feature allowing the user to command outputs manually for troubleshooting. The user programmable objects have allowed the development of some very advanced features. One is a selectable timebase scrolling graph (a show/hide control object toggles between graphs set for different timescales). A password protected numerical entry box denies access to setup parameters until a 4 digit password is entered for that screen. I have connected the RS-232 output to a modem. This is issued text commands when alarm conditions exist, and can dial a numerical pager to alert remote operators. This software has been installed at about 10 sites so far across the country and has been very well received. Submitted by: |
| Application: DL240 PLC controls industrial cooling system at a paper company Products Used: DL240 PLC, various analog I/O, DV-1000 operator interface Description: A DL240 PLC with a 9-slot base handles all logic operations to control an industrial cooling system for a paper company. The system senses water temperatures and pressures and outputs analog signals to the variable speed drives for the respective cooling tower fan and pumps. Analog pressure and temperature signals are input to help determine motor speeds. An auto-changeover routine in the ladder logic switches to a backup pump in event of pump failure. The DV-1000 unit enables the user to adjust setpoints and timer values, and to view the status of the various system components. A toggle switch lets the user scroll through 4 screens of data in the message display mode. An alarm (audible and visual) is actuated for high temperature and for pump failure/switchover. Timers are used for a smooth sequential startup of pumps and the cooling tower fan. Submitted by: |
| Application: DL240 PLC counts glass bottles and makes production data available to management Products Used: D2-240 PLC, PC-205-DDE PC link software Description: A D2-240 and sensors for sensing transparent glass bottles are used to accurately count the number of glass bottles manufactured and sorted at one of the premium glass bottles manufacturers in India. The ladder logic, incorporating the real-time clock and counters, counts and stores the data on an hourly, shift-wise, daily and monthly basis. The line speed is monitored with signals from the variable frequency drives. This data is transferred continuously to a PC over a serial link using the DDE driver, where it is transferred to standard database software like Microsoft Excel. This data is formatted here per the MIS requirements and the efficiencies are calculated. The formatted data in Excel is used for MIS report generation and printing using VB macros. This standard Windows compatible data format makes it available to other departments over the ERP network. The end result has been displacement of manpower (with a payback period of as little as 12 months!), better production scheduling, inventory management and online data availability for the sales personnel. Submitted by: |
| Application: DL240 PLC goes for a tractor ride to monitor agricultural seeding operations Products Used: 12v powered D2-240 PLC, DC inputs, OP-640 operator interface
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| Application: DL240 PLCs linked in a work cell produce PVC appliance gaskets Products Used: DL240 PLC, D2-16ND3-2 DC inputs, D2-08TR relay outputs, OP-413 setpoint panel Description: The DL-205 with the 240 CPU is used to drive two (2) separate, but similar machines, that are linked together in a work cell. The function of the (9) work cells is to cut to length and heat fuse sections of PVC appliance gaskets. I wrote the program with DirectSOFT in "stage" format, which I read about in the DL-205 Users Manual. The interesting thing about this application is that the two machines operate independently. Each machine has its own start/reset, emergency reset, and emergency stop buttons, but share a PLC and output power supply. I had been advised by a few fellow engineers and co-workers that this either wouldn't work or would be nothing but trouble. However, the low cost, ease of installation and programming and excellent technical support have helped me to build a control system with a production capability of 1920 cycles per 8-hour shift, per machine. I am currently adding OP-413 setpoint panels to each work cell, so the operators can adjust constant timer values for themselves; this will cut down on maintenance calls for minor adjustments. Future plans include linking PLCs together with H2-ECOM Ethernet modules for monitoring and broad based control. Submitted by: |
Description:
This application involved the rebuilding of a Mateer Model 37A dual head
auger filling machine with a horizontal conveyor. I was asked to build
a fully automatic control system for the machine. The machine had to fill
two bottles with powdered spice products in rapid sequence. I selected
a DL205 PLC for the job. This project was extremely complicated because
two auger heads needed to move at the same time, with each head filling
its own bottle. After each fill cycle there needed to be finger stopper
pistons on the horizontal transport conveyor working with photoeyes to
sequence the bottles for filling. Because the bottles were small, they
filled up fast. The machine was estimated to fill 140 bottles a minute.
This speed is too fast for the human eye to see in order to analyze a
problem if the machine is not working correctly.
Description:
Several control systems utilizing the DL205 PLC control the speed of pumps
and powder feeders to create seed pellets. The system uses a DirectTouch
M-320 operator interface, and an H2-ECOM Ethernet module out to a PC,
where the setup for the machine is stored in an Access database. The database
and control software is controlled with a Visual Basic program and interfaced
using DS-Data Server program. The machine is run manually from the operator
interface, and the program logs all the starts, stops and speed changes.
When the batch is done, it is saved in the database so that it can be
recreated automatically at a later date, as well as being able to provide
statistical data on batches and clients.
Description:
This system was developed as a joint project with Starco Mfg. Inc., manufacturers
of the Milton Precision Planter. The planters are pulled by a standard
agricultural tractor; magnetic pickups mounted on the seed wheels of the
planters provide motion indication to the PLC. The PLC processor physically
resides on the toolbar inside a weatherproof enclosure and is powered
directly from the tractor's 12 V supply. Communication is routed to the
OP-640 operator interface inside the cab of the tractor and provides the
operator with alarm indication and seeding rate. Though the entire system
is exposed to high vibration and extremely dusty environments, there has
not yet been a system failure. Further agricultural applications are currently
being pursued in association with Starco.