Auto Hook Machine HMI Upgrade

The task here was to improve the machine interface to make the machine easier to use for the operators.

We used Siemens 22” Comfort Panel Pro for this project- this gave us lots of space for some fantastic visuals.

We worked in collaboration with Thunderstorm FX on this project who provided us with a 3D model of the entire machine and some amazing image renders.

Multi-layered images gives the operator the ability to zoom into the sections of the machine to pin-point fault locations as well as IO status at any location.

The finished product was a very neat easy-to-use HMI

Setting Machine HMI Upgrade

Our customer asked us to replace their old Red Lion HMI with a ProFace screen on their setting machine.

The existing screen was confusing to use as there was a lot of unnecessary information on key screens. We redesigned each screen so that the operators are only presented with information relevant to the task they want to undertake.

We chose the ProFace PFX SP5700TPD for this project. Its 15” widescreen format meant that we could fit some nice graphics on this.

As well as upgrading the HMI we also changed the PLC code so that the machine was no longer sequence-based. The new code allows the machine to be moved to any position in manual mode and can continue its process when switched back to automatic mode.

S71500 G120C Training Station

Another training station built for a new customer. This station was built using common spare parts that are in use at their site.

The station has a Siemens failsafe 1511F CPU coupled with a G120C drive and a 7" Comfort HMI all power via a single 230Vac supply, ideal for use in an office or workshop.

The HMI has some pre-designed screens for control of the drive with a detailed view of the ZSW and PZD signals on the fieldbus. The main purpose though is for the users to create their own screens and develop skills in TIA software.

Recycling Plant PLC Upgrade

We were asked to replace the PLC's at a recycling plant The existing control system consisted of 3 PLC's running a shredding/recycling line with no HMI present.

Stoppages were happening often but without any HMI, the operators and maintenance were spending valuable time chasing wires inside the control cabinets trying to discover what caused the stoppage.

We installed an S7 1511 with ET200SP remote IO and a Comfort HMI on Profinet. The result was a user-friendly system with diagnostics and alarm history. Hand controls were also added which were not available before the upgrade.

Belt Welder Control Unit

We developed and built this bespoke control unit for melt-splicing timing belts. Our client asked for our help to produce a control system that would allow them to weld their timing belts without having to manually control the heating plate temperature.

Each belt type has its own splicing temperature and dwell time. The temperature must be maintained +/-5degC for the required time before being cooled using a water pump.

Their method for splicing belts involved manually switching on and off the top and bottom heating plates of the heating device to maintain the required melt-temperature whilst watching the plate temperatures on a hand-held thermometer. When done, the plates are cooled by switching on the water pump. It's a complicated procedure that requires concentration and good timing. The process often resulted in many wasted belts.

We worked with our client to design an automated method to do the same task. The project developed and we came up with a great product which does the job with a simple press of a button.

Clay Preparation S5 Upgrade

Our clients asked us to upgrade their existing Siemens S5 system and replace it with the latest Siemens PLC. For this we used a Siemens S7-1515.

The existing SCADA package was replaced with a 19" Comfort HMI which does a great job of displaying the system overview as well as giving full control of all plant devices.

Rather than make a direct software conversion they asked us to re-write the control logic in a way that could be understood more easily by their maintenance team. This was a fantastic opportunity as the system involves multiple PIDs for the process control of their base product and a clever system for regulating slurry density.

A Pilz Multi safety PLC was already being used to manage the safety functions of the equipment so we networked this with our PLC using Profinet to read the Pilz data which gives message alerts on the HMI and shows the operator where the trip has occured.

Brick Cutting Machine

We designed and commissioned the control software for a brick making machine for a leading brick manufacturer.

Our client had been let down by their current system integrator mid-way into this project and came to us for advice on how to complete the project. We were able to develop software for the machine control and designed some intuitive HMI screens for the existing hardware.

Siemens S71500 was employed as the controller and the field IO was all Siemens As-i which gave us scope for lots of on-screen diagnostics.

The final result was a machine with multiple control points and extensive control adjustments available to the operators which previously was done by moving switches in the field. As-i diagnostics provide a valuable tool for on-site technicians to fault find via the HMI.

Extruded Brick Making Machine S5 Upgrade

This control system was commissioned by us at a brick manufacturing facility in Leicester.

For this we used a Siemens 1500 PLC coupled with multiple HMI's which replaced the existing Siemens S5 system.

The new system provides operators with much simpler manual controls and fault diagnostics.

Production statistics show historic values for units produced and wastage.