Recent Projects:

PC based Cell Controller integrates CNC, Bar Code Reader, Bar Code part marker, Digital I/O, Poke Yoke, HMI, and data logging functionalities.

Custom PC based Cell Controller written in C# with standard Microsoft Development tools to provide an operator HMI, integrate a data stream from a CNC machine, drive a Video Jet part marker and provide Poke Yoke functionality with the bar code reader, while also allowing part and operator tracking via the information printed on the part. Tri level password for controlled access to system, system logging by day. Digital I/O interface via an ethernet Modbus TCP connected I/O block. This multi threaded application runs on standard low cost Intel PC hardware and can obtain reliable 75 ms scan times of the I/O block while processing other functions including data logging and part tracking. Software runs on Windows 10 Pro and was designed to survive unannounced power outages while retaining tracking data. Modern PC hardware with a Solid State Disk insures long life. Software source code is owned by customer so they can be assured of system viability long into the future.

Siemens S120 Multiaxis Coordinated motion system with Siemens S7-1500 PLC based motion control

Six Axis Drive Siemens S120 Servo Drive system with S7-1500 Integrated motion control and Siemens HMI to control a custom machine for a metal forming application at an Automotive Tier 1 supplier.

Custom Mobile Equipment for Farm Automation

Automation of mechanisms using a custom control box using a PLC, screen, stepper motors, and Gecko stepper drives to robotize the machine and allow autonomous operation in farm field conditions. Custom mechanical work to upgrade the generating capacity of the mobile platform.
An NDA limits my ability to further elaborate on this cutting edge machine development.

Flow WaterJet CNC control replacement

Replaced original Flow control with new Open Source LinuxCNC PC based control in conjuction with a Siemens S7-1200 PLC to handle the high pressure pump system (100hp) interlocks and monitoring system. Replaced the existing Yaskawa Servo drives with new Teco servo drives.Replaced the original control panel that was not air tight with a new air tight / air conditioned control panel that housesthe control PC (custom assembled), the CAD PC and the new Siemens PLC system. The customer fabricated new operator stands.
We worked with the customer to minimize costs by utilizing their skilled labor to assist with the installation.

 

A second Flow waterjet control replacement is scheduled at the same plant.

Faustel Web Converting Machine control system retrofit

Replaced an existing Siemens 505 PLC system with a Siemens S7-1500 PLC system. Replaced two 12" CTC Touchscreens with two Siemens TP1200 Touchscreens. Replaced 8 obsolete Siemens Vector Drives with a new Siemens S120/CU320-2 DP common DC bus drive system. Programmed the new equipment to mimic the operation of the old equipment including the unwinder and winder functionality at the ends of the line. Tearout, installation, and rewiring was accomplished over a two week shutdown period.

The main rack of the PLC that was removed and replaced:

 

Custom Machine Re-Control

Removed controls from existing rubber processing stations and replaced with new control panel with Siemens S7-1200 controls and a Siemens TP1200 Touch screen. The Siemens TP1200 Touch screen provides basic operator controls along with the rewired pushbutton panel and provides an OPC server that will be utilized to gather process data for SPC.