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CASE STUDIES

Line Controls Upgrade - Hilliard, OH
Upgraded old relay panels, pushbutton controls, and external PID controllers to touch screen networked HMIs and PLC controls. (1) Allen Bradley Control Logix processor, PowerMonitor 3000, (23) Allen Bradley PowerFlex 70 Drives, Position Indicators, Encoders, (4) Panelview 1000 Plus series touch screens. Communications included Data Highway +, EtherNet and DeviceNet.

PLC and HMI Upgrades - Suffolk, VA
Worked with Rockwell Automation to upgrade obsolete Allen Bradley Process Logix (PLX) processors to Allen Bradley Control Logix Processors (CLX). This upgrading process involved rewriting all of the code in the Process Logix processors in to ladder logic for the Control Logix processors. The Batch View screens were also upgraded and rewritten to new Allen Bradley Factory Talk View SE (RSView) screens. The conversion process for this food and beverage plant took over a year and a half utilizing down time every five weeks for the upgrades.

Wet Scrubbers - Marietta, PA
Aided in design and provided system programming while overseeing installation of a wet scrubber emission controls system. System required 7 PID controlled flows including water, air and temperature. Also provided remote substation monitoring and alarming. (2) 800hp Robicon Drives, Wonderware programming, Allen Bradley Drives, Allen Bradley PLC5/60, (2) Flex I/O racks, (1) 1771 Remote Rack. Communications included Data Highway +, EtherNet and Remote I/O.

Automated Batching Operation - St Helens, OR
Upgraded existing controls by moving external PID controllers, pushbuttons, and alarms in to PLC. Managed project electrical and controls installations. Changed (4) PLC processors and Wonderware I/O servers from Data Highway + to EtherNet communications. Merged (2) Wonderware applications in to one. (16) PID Loops, (7) Wonderware stations, (1) Allen Bradley PLC 5/40E, (3) Allen Bradley 5/40, Allen Bradley 5/20. Communications included Data Highway +, Remote I/O and EtherNet.

Specialty Production Line - Marietta, PA
Designed electrical equipment and automated high speed specialized tile production line. (Totaling over $13 million.) (1) Allen Bradley PLC5/60, (3) Allen Bradley PLC 5/40, (2) Allen Bradley PLC5/20, (3) Allen Bradley SLC500 (5) Remote Racks. (2) Ormec Servo Systems, (6) Panelmate 4000 Series HMIs, Panelmate 1700 Series HMIs. Communications included Data Highway + and Remote I/O.

Machine Guarding Safety Compliance - Suffolk, VA
Performed a safety audit in order to provide safety methods and safe equipment that meet NFPA and ANSI standards without interrupting or changing the work practices or operations of the food and beverage plant's packaging machinery. Made the necessary machine classifications, device installation and replacements, wiring changes, guarding, and documentation in order to comply with codes.

Palletizer - Marietta, PA
Completely re-programmed an existing palletizer to allow more efficient movements thus allowing higher production speeds and reducing downtime. Integrated palletizer in to an existing production line and added remote system monitoring. Allen Bradley PLC5/40, Allen Bradley PLC5/20, (2) Allen Bradley SLC500, (2) Panelmate 4000 Series HMIs, Many Allen Bradley drives, IEC starters. Communications included Data Highway + and Remote I/O.

Palletizer - Pensacola, FL
Upgraded existing palletizer program and controls from outdated Modicon PLC, obsolete drives and push button control. Allen Bradley ControlLogix, PanelView 1000, Allen Bradley Drives. Communications included DeviceNet and EtherNet.

Paint Booth Servo - Hilliard, OH
Automated a new servo driven paint booth system and interfaced with the existing production line. Ormec servo drive system, Allen Bradley PLC5/40, Panelmate 4000 Series HMIs. Communications included Data Highway +, serial and Remote I/O.

Paint Booth Servo - Marietta, PA
Automated a new servo driven paint booth system and interfaced with the existing production line. Ormec servo drive system, Allen Bradley PLC5/40, Panelmate 4000 Series HMIs. Communications included Data Highway +, serial and Remote I/O.

Paint Booth Servo - Pensacola, FL
Automated a new servo driven paint booth system and interfaced with the existing production line. Added PID paint flow control. Allen Bradley ControlLogix with SERCOS for motion control, Kinetix 6000 servo drive system, PanelView 1000 Allen Bradley Drives. Communications included EtherNet, SERCOS, Data Highway + and Remote I/O.

Air Handling Units - Reading, PA
Controlled 4 air handling units using PID control for manufacturing area to regulate air pressure in building and log differential pressure for EPA. This change was to correct an Environmental Protection Agency (EPA) violation. Communications included Allen Bradley PLC 5/20, Allen Bradley Drives, Digital Recorder, Data Highway + and Remote I/O.

Oxidizers - Reading, PA
Upgraded temperature PID control for two oxidizers to regulate at 1500 degrees. This change was to correct an Environmental Protection Agency (EPA) violation. Allen Bradley PLC 5/20, Allen Bradley SLC500, Honeywell temperature controller. Communications included Data Highway +.

Press - Macon, GA
Automated a new 400 Ton punch press and integrated in to existing production line. OmniLink Controller, Allen Bradley PLC5/40, PanelView 1400, Allen Bradley 1336+ Vector Drive with encoder feedback. Communications included Data Highway + and Remote I/O.

Press - Macon, GA #2
Automated a rebuilt 200 Ton punch press and controls while integrating in to existing production line. OmniLink Controller, Allen Bradley PLC5/40, PanelView 1400, Allen Bradley 1336+ Vector Drive with encoder feedback. Communications included Data Highway + and Remote I/O.

Press - Marietta, PA
Automated a new 250 Ton punch press and integrated in to existing production line. OmniLink Controller, Allen Bradley PLC5/20, PanelMate 4000 Series HMIs, Allen Bradley 1336+ Vector Drive with encoder feedback. Communications included Data Highway + and Remote I/O.

Press -Marietta, PA #2
Automated another new 250 Ton punch press and integrated in to existing production line. OmniLink Controller, Allen Bradley PLC5/40, PanelMate 4000 Series HMIs, Allen Bradley 1336+ Vector Drive with encoder feedback. Communications included Data Highway + and Remote I/O.

Wonderware - St Helens, OR - Area #1
Upgraded (7) existing InTouch Wonderware stations, Recipe Manager and I/O servers to latest version with Data Access Server with redundancy. Communications included Data Highway +, EtherNet.

Wonderware - St Helens, OR - Area #2
Upgraded (8) existing InTouch Wonderware stations, Recipe Manager and I/O servers to latest version with Data Access Server with redundancy. Communications included Data Highway + and EtherNet.

Wonderware - Marietta, PA
Upgraded (4) existing InTouch Wonderware stations, Recipe Manager and I/O servers to latest version with Data Access Server with redundancy. Combined two existing InTouch applications in to a single working application. Communications included Data Highway +, EtherNet CIP, Ethernet TCPIP, and OPC.

CO CEMS System - St Helens, OR
Integrated carbon monoxide (CO) Continuous Emission Monitoring System (CEMS) in to current control network in order to meet EPA compliance and also to log status in Data Historian. (2) Allen Bradley SLC500. Communications included Data Highway +.

Feeder/Stacker - Marietta, PA
Automated a new Feeder/Stacker combination unit in a high-speed production line. (1) Allen Bradley PLC 5/60E, (2) Panelmate 4000 Series HMIs. Communications included Data Highway + and Remote I/O.

Equalizers - Lancaster, PA
Automated a new multi pass dry saw using a servo system and integrated in to an existing line. Kohl Morgan Servo system with high-speed encoder feedback to an Allen Bradley SLC5/04, (2) Panelmate 4000 Series HMIs. Communications included Data Highway + and Serial.

Continuous Flow Machine - Macon, GA
Automated new equipment to connect two production lines together to allow a continuous flow of material. (1) Allen Bradley PLC 5/40, (2) Allen Bradley PLC 5/20, (1) PanelView 550, (2) Panelmate 4000 Series HMIs. Communications included Data Highway +, Remote I/O and EtherNet.

Product Positioning - Hilliard, OH
Automated equipment to accept product then modulate two conveyor's speeds on-the-fly to position the product on the next piece of equipment during the equipment's window to accept the product. Allen Bradley PLC 5/40, (2) Allen Bradley PowerFlex 70 Drives with encoders, (4) Panelmate 4000 Series HMIs. Communications included Data Highway + and Remote I/O.

Product Sterilization - Mount Holly, NJ
Provided equipment programming for pharmaceutical product sterilization in an explosive rated area. Allen Bradley PLC5, Allen Bradley Data Liner, (2) Allen Bradley 1336+ Drives. Communications included serial and Remote I/O.





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