Human-machine/machine-machine interfaces continue to provide users with greater flexibility and shorter setup time, as the following real-world examples illustrate.
Optimizing Assembly System Performance
Mikron Assembly produces custom assembly systems for high-volume production of small components. Its Flexcell linear assembly cell can produce 300,000 high-precision parts per day. To meet the flexibility in design required by North American customers, Mikron wanted to offer a PLC-based control system option in addition to its PC-based system. Mikron chose the Allen-Bradley SLC 5/05 programmable controller (shown here), connected over Ethernet to an A-B VersaView industrial computer with touchscreens running the Rockwell Software RSViewMachine Edition HMI.
Because it runs on multiple operating systems and supports open and embedded HMI solutions, the software helps Mikron reduce HMI development time. Machine performance/downtime reports are "invaluable for machine debug, acceptance, and production when Flexcell reaches our customer''s plant," according to Sean Flanagan, controls project manager at Mikron. (For more, click here.)
Bringing New Displays Online -- In a Hurry
Thin Client hardware has increased efficiency at tape manufacturer Shurtape Technologies. The company chose Wonderware''s FactorySuite and ACP''s ThinManager in its efforts to meet customer JIT and quality demands.
It once took Shurtape some three hours to load and configure the appropriate PC software each time a new display was required. With Thin Clients, a new display can be added by plugging in and turning on a Thin Client. The switch has resulted in project cost reductions of 40%. (For more, click here.)
Keeping People Connected, Anywhere
DataNet OPC, a software solution developed by AutomationDirect supplier/partner BizWareDirect, displays real-time data on a web page, with no HTML programming required. It also logs data into a text file. Through a web-based configuration facility, users specify which sets of data should be logged, and at what time intervals. (Pictured, DataNet OPC user W.W. Henry''s main display screen, which shows each tank number, material/product being held in the tank, and amount of material in inches and in gallons.)
"Before installing this program, we only had one reporting computer, located in the back of our plant lab," says Tony Holmes, purchasing specialist for flooring adhesives manufacturer The W.W. Henry Co. DataNet OPC has reduced reporting errors by 99%. (For more, click here.)
Maintaining Product Quality
Arla Foods'' Christiansfeld Dairy Centre in central Denmark turned to Wonderware''s InTouch HMI to help improve traceability. "In order to access vital process information, we had to wade through piles of reports," recalls Erik Veslov, production manager at the Christiansfeld plant.
Now data can be accessed in real-time by the Wonderware system, which provides data visualization and control via the InTouch HMI and product genealogy from InTrack software. This traceability "actually reduces the risk of having to recall a large amount of product because we have detailed information on each batch," Veslov adds. (For more, click here.)
Upgrading a Legacy System
Facilities IT solution provider O & M Engineering, Inc needed to unlock the data in a client''s FMS, and found an answer in Advantech technology. The end user wanted to enhance the capabilities of its early generation Johnson Controls'' Metasys Building Automation System. The traditional approach to installing the system is to hardwire the N2 bus with serial cable throughout a facility, which is often redundant to networks already in place. (Shown here, Metasys test lab at The S4 Group; Adam 4571 Serial Server is being used to extend the N2 bus over Ethernet.)
The N2 Router "extends RS-485 N2 field bus over existing Ethernet infrastructure," says Steve Jones, managing partner of the S4 Group. Advantech''s UNO-2059 provides the necessary CPU and memory for the project and multiple ports with built-in support for RS-485. The 586-grade platform offers USB and PC card interfaces to meet I/O device expansion needs. When more ports are needed, or the N2 bus needs to be extended over their Ethernet network, S4 uses Advantech''s ADAM-4570 and 4571 models as a gateway between RS-232/422/485 and Ethernet interfaces. (For more, click here.)
Reducing Downtime
Downtime is the biggest cost factor in the roll-fed labeling industry, says B & H Labeling Systems product manager Dr. Beverly Politzer. Changeovers to accommodate a new container size or label can delay production for hours. B & H has taken on downtime with a new multiaxis servomotor labeler. The brains of its Marathon SMARTdrive technology reside in a Siemens'' SIMATIC S7300 PLC that is connected via Profibus to a 10 in. MP270 B HMI.
"We knew we could have a 30% smaller footprint by placing the components in a smaller box," Politzer notes. And the new technology has "allowed us to reduce changeover time by 50%." (For more, click here.)