234 LAURELWOOD DRIVE, Russellville, Alabama 35653

The customer needed a small PLC controlled system with HMI that would allow them to turn on and off 4 different 480VAC heaters, a 5 HP exhaust fan and 3 HP pump. The system I designed was based around the Automationdirect Click PLC and Cmore Micro HMI. Both allowing the customer to easy of setup and monitoring the system temperature and graphs of the tank temperature. 

 

Contact: Bill floyd

               (256) 627-7389 or billf@icc-llc.com


The customer needed a simple on/off control station that would allow them to mount the control cabinet outside. I desgined a control system with a 60AMP disconnect to control with two motor contactors to allow the operator to start and stop each item as needed. The customer also need 4 amps @ 120VAC to control a chemical pump. I added a 1 KVA transformore to handle the chemical pump and control circuit needs.

 

The customer asked for a custom machine to index 4 different profile beams used as the side rails on 53' flatbed trailers. I designed and built this machine to move the beam using Delta Motion Controller RMC75S, Automationdirect DL-250 CPU and Cmore HMI to allow the operator to enter the wanted index distance.

 

After the trials of this machine it will be setup to control the a stamping press for automaticly cycling the press after the material has moved.

 

The customer had purchased a used natural gas powder coat curing oven 24' X 40' from a supplier and needed an control system to safely light the gas burner and control the temperature. This control system has multiple safeties hard wired in the system working with a Honeywell 7800 flame controller, Click PLC and Cmore HMI. The PLC will inform the personal on the HMI of any issues or faults. The HMI will data log the oven temperature on a USB key which that data can be imported in to Microsoft Excel in the even they need to pull a temperature profile for a certain day. 

600 Ton Press brake 2 axis Hydraulic control system -

The customer had a 400 ton press brake which due to the age and temperature in Alabama during the summer months was having issues with the hydraulic system staying in a normal operating range.

 

We built this system to pump 17 gallons of minute in a kindey loop configuration to circulate the oil through a double pass cooler to maintain the temperature at 110°F. While the system is cooling the fluid we are also filtering the oil to 3 microns.

 

53' custom Beam feeding system 0.005" +/- Tolerance -

Pines #1 - retrofit Vertical hydraulic tube bender -

control system for six 2,000 ton hydraulic molding presses -

 

The customer manufactures lawn mower blades and wanted to retrofit 2 two axis milling machines. The old design used dead stops which the operator would have to adjust to obtain the wanted cut length. I designed two hydraulic units on for each mill. Each milling machine cut length is being controlled by a single RMC100 4 axis Motion controller by Delta Comptuer Systems. The operator enters the wanted cut length in to the HMI which is communicating to the Automationdirect DL-260 CPU. The CPU is communciating to the Delta RMC100 via Modbus issuing the commands and controlling the cut length with a tolorence of 0.004". The customers required tolorence was +/- 0.125".

 

Both milling machines are controlled by the above DL-260 CPU which is also issuing the load and unload commands to the two Motoman Robots used for loading the machines. The loading tables are using Terminator I/O modules communicating to the PLC via ethernet.

 

We were able to save the customer a lot of money by using a single plc, motion controller to control two machines using one control system and two HMI's. The dual HMI's give the operator the feel of two different control systems in one package.

Aquence 866 Coating control system - 

The customer has two different 53' dual gun beam welders. I was asked to design something that would allow the operator to adjust each welding gun without the operator having to reach inside the machine as it was running. I designed a small control system using a stepper motor and driver that would allow the operator to move each gun separately via two joy sticks. The joy sticks are mounted in the operators control station, this allows the operator too make minor adjustments to each gun as the system is welding without the operator having to lean over in to the machine as it is running, removing any safety concerns.

 

Pines # 5 VERTICAL hydraulic tube bender controls -

2 AXIS HYDRAULIC BEAM PUNCH CONTROL SYSTEM WITH POSITION FEEDBACK

dual rail beam indexing machine-

A control system was designed to control 2 20GPM RO Units to control the level of a 4,000 gallon tank of RO water. The waste water was stored in a 1,500 gallon tank to be pumped  when the waste water level reached the programmed level. The operator entered all the required levels on a 8" EA9 HMI from AutomationDirect. The PLC choosen was DL-06DR with a 4 Channel 0-10V analog input card. Each tank was outfitted with a ultra sonic level detector which provided the analog feedback to the plc of each tank level. The plc also monitored all overloads and fuses and will display any faults on the HMI and sound a alarm. The RO feed line pumps were controlled by monitoring a pressure transmitter mounted on the line. As the pressure dropped the plc would start feed pump as needed.

 

The customer purchased a used 10 ton overhead crane which had no control system. All travel directions motors (North, South, East, West, Up & Down) are single speed motors. The customer requested the up and down motion to be dual speed. To save money, I designed the system to control the up and down motion control using a VFD. The VFD will control the speed via the analog output from the PLC. The system will be controlled via wireless remote control.

 

Pines # 3 Horizontal hydraulic tube bender controls -

The customer purchased a Pines bender which had a custom control system from the machine builder which was obsolete and the customer was unable to find the parts to get the machine up and running. I removed the obsolete control system and designed a control system using a AutomationDirect DL-06 PLC and EA9 8" Color Cmore operator interface. The plc has the abilty to assign the first 2 inputs as a high speed counter to allow feedback from the 2,500 pulse encoder. The logic I have designed allows the operator to enter up to 12 bends (for this machine).

 

Once the parts are milled and finished the part is removed from the milling machine and the robot will load another raw part in to the milling machine. The finished part will travel down a conveyor and be stacked until a quanity value is reached in the stack. At the time the plc will index the conveyor belt 6" to allow room for the next stack.

The customer designed a die to punch holes in a 53' of extruded aluminum and needed a hydraulic unit and control system for the punches. I designed & built  a 30 gallon hydraulic unit using a pressure compensated hydraulic pump on 7.5HP motor. The punches are controlled using multiple 4" bore hydraulic cylinders with MTS sensors gun bored in to the cylinder for position feedback. A Delta RMC 75 is handling the motion control to determine the speed, position and motion of each punch. The positions and speed values are entered in a EA9 Cmore HMI from Automationdirect and communicated to a Allen Bradley 1500 Micrologix PLC. The PLC is in constant communication with the RMC 75 via serial communications.


NOTE: AS OF NOV 2, 2016 THIS PANEL IS STILL IN THE PROCESS OF BEING BUILT, ANY PHOTOS POSTED ARE PROGRESS PHOTOS ONLY.



 

The customer has 3 different heat treating lines which harden law mower blades after they are manufactured. The customer wanted at data acquisition system that would capture the temperature every minute of 3 different high heat temperature valves (type K) thermocouples. They also wanted to capture the temperature of all 3 quenching zones every minute. I designed a system using a DL-06 PLC and thermocouple input cards that would monitor each thermocouple. This data was being logged in to a Cmore EA9 HMI and stored to a USB flash drive. This allows the production managers to remove the USB flash drive and download the recordings in to Microsoft Excel. This can also be done using the Ethernet port built in to the HMI and would allow the managers to retrieve the data over their network.

 

six zone temperature data recording system for 3 heat treating lines-

The customer purchased a Pines bender which had a Allen Bradley Micrologix that was OEM password protected and the controls shop that installed the PLC went out of business. Instead of replacing it with another Allen Bradley I removed the obsolete control system and designed a control system using a AutomationDirect DL-06 PLC and EA9 8" Color Cmore operator interface for the same cost as what the PLC alone would have cost. The plc has the abilty to assign the first 2 inputs as a high speed counter to allow feedback from the 2,500 pulse encoder. The logic I have designed allows the operator to enter up to 12 bends (for this machine).

 

This is the 3rd machine that I have rebuilt the controls and with this design they can keep a low supply of spare parts since all three control systems are the same.

 

outdoor pump, blower & chemical pump control -

The customer purchased a Reverse Osmosis system and wanted PLC control, data logging for water quality and the ability to set the RO storage tank level settings and alarms with ease.

 

I designed this system around a DL-260 CPU, Hanna Conductivity Meter and Banner QT50 Ultra Sonic Sensor for tank level. The Hanna Meter informs the plc of the water quality through an analog output in to the plc. The operator can enter the alarm levels for the water quality, tank levels and acknowledge them from the HMI.

 

The PLC is also tracking RO run times for maintenance.

Reverse osmosis control system - 

4 axis hydraulic milling retrofit with 2 motoman 6 axis robots for loading - 

The customer had an obsolete control system which finding parts or someone to service was just about impossible. The old control system used mercury pressure sensors to control the steam pressure inside a 5' diameter X 30' Long Autoclave. The customer wanted the ability to setup up to 6 different cure steps. This would allow them to enter a pressure via the HMI and cure time, once that time completed it would move to the next pressure and time. The customer also wanted email notification when the system started, was at pressure, completed and discharged.


I designed the system using a Do-more CPU and C-more EA9 HMI, This allows for plenty of memory and the ability to save cure cycles to the internal SD card in the HMI. The stored data can then be imported int o Microsoft Excel. The customer now has the ability to log in to the system to change or view anything as if they was standing  at the HMI from anywhere in the world, using a laptop, tablet or smart phone.

 

Pneumatic heated screen press for manufacturing filters used on lawn & garden equipment

The customer had an old Pines control system on machine and which had failed. Instead of replacing purchasing obsolete & over priced parts from the machine manufacture, they allowed us to build them another new control system using a AutomationDirect DL-06 PLC and EA9 8" Color Cmore operator interface. The plc has the abilty to assign the first 2 inputs as a high speed counter to allow feedback from the 2,500 pulse encoder. The logic I have designed allows the operator to enter up to 12 bends (for this machine).

 

This is the 5th machine that I have rebuilt the controls and with this design they can keep a low supply of spare parts since all three control systems are the same.

 

Complete control system for 80 PSI Autoclave

The customer has two different 53' dual gun beam welders. I was asked to design something that would allow the operator to adjust each welding gun without the operator having to reach inside the machine as it was running. I designed a small control system using a stepper motor and driver that would allow the operator to move each gun separately via two joy sticks. The joy sticks are mounted in the operators control station, this allows the operator too make minor adjustments to each gun as the system is welding without the operator having to lean over in to the machine as it is running, removing any safety concerns.

 

dual 20gpm ro control & dual waste water pump control system -

stepper motor control system for 53' dual beam welder machine 1 -

17 GPM Kidney loop hydraulic cooling system -

 

Here the customer had a machine which had an old plc (15+ years)installed in it. But the machine builder at the time had OEM password protected the logic from accessing it. The PLC failed and at which time the customer had discovered the machine builder had went out of business. I removed the old control system and installed a new PLC and HMI.

 

The PLC is a Automationdirect DL-06 which is communicating to a 8" HMI. The customer wanted the abilty to program up to 16 different bends per cycle along with hold times after each bend. I'm using the high speed counter function in the plc to monitor the 2,500 pulse encoder on the machine and displaying the angle of each bend.

 

We never password protect any plc and always make sure the customer has copies all of all the programs installed on disc and printed versions.

ICC-LLC

INDUSTRIAL CONTROL CONSULTANT LLC

Aquence 866 Coating is used to product a smooth, black, organic coating on ferrous metal surfaces. The process provides low cure coatings with good corrosion resistance, solvent resistance, adhesion, flexibility and hardness with the use of solvents or heavy metals.

 

The customer  had us to design a control system for all 7 stages. The system was designed using a Automationdirect DL-260 CPU with a 10" Color HMI. The PLC also controls 4 dryers using 4 solid state rectifiers using 4 PID loops to hold the temperature at the wanted level.

 

The program was designed to allow the system to start automaticly at a programmed time which can be set via the HMI. This allows the system to start heating up the required stages without any human interactions. The HMI gives the operator the ability to set mixer speeds, temperatures, spray times and informs the operator of any alarm conditions.

The customer is currently building a robotic weld cell in-house  and asked for me to design a control system to start, stop & safety functions. Safety fencing will surround robotic weld cell and light curtains will protect the operator working area. I've designed the system using a Allen Bradley 1500 plc (customer wanted AB)  which will communicate to the Cmore HMI that will allow the operator to start and stop the system as needed from the HMI.



 

robotic weld cell control system to automate wing plate welding

The customer has a pneumatic heated screen press with molds used to mold the screen on to a filter for the lawn & garden industry. The customer wanted a new control system that was simple to use, easy to configure and troubleshoot. I designed a system using a DL-06DR Automationdirect CPU along with a set of light curtains to protect the operator while the machine is in operator. The system timers and I/O status can be monitored from a 3" Cmore Micro HMI, which will inform the operator of any issues, track production and life cycles of the machine for maintenance needs.



 

The customer has two different 53' dual gun beam welders. I was asked to design something that would allow the operator to adjust each welding gun without the operator having to reach inside the machine as it was running. I designed a small control system using a stepper motor and driver that would allow the operator to move each gun separately via two joy sticks. The joy sticks are mounted in the operators control station, this allows the operator too make minor adjustments to each gun as the system is welding without the operator having to lean over in to the machine as it is running, removing any safety concerns.

 

stepper motor control system for 53' dual beam welder machine 2 -

Pines # 2 Horizontal hydraulic tube bender controls -

The customer had a old press brake that could not keep both sides at the same position. I desgined and built a new control system using a Delta Motion  RMC100 2 axis controller and two MDT Sensors to sync both axis. The base of the control system is AutomationDirect  DL-260 CPU and 8" Cmore operator interface. This allows the operator to adjust the press home and bend postions via the HMI an d download the new positions to the RMC. The PLC monitors both hydraulic pumps, hydraulic temperature and fluid level and displays any faults on the HMI.

 

600 Ton Press brake 2 axis Hydraulic control system -

1,000 Gallon 200 AMP Main For Heaters, pump & exhaust fan control system -

10 ton overhead crane control system with wireless control -

 

The customer had a 1970 600 ton press brake with outdated controls and hydraulic system. LineCo Hydraulics was contracted to design, build and install the hydraulic system. I designed the control system using a Allen Bradley 1500 PLC, Delta RMC 101 Motion Controller to handle motion commands for the press. Each axis position was monitored by a MTS sensor connected to the RMC. The RMC was communicating to the PLC via a serial connected to the RMC.

 

This was a challanging system, the old control system consisted of 6 PLC's which were obsolete and the customer had been purchasing used ones from ebay. They requested a quote for a system that would have a single plc to control all six hydraulic presses.

 

I used a Automationdirect DL-260 CPU, 6 Cmore HMI's (1 for each press) and 6 Terminator Remote I/O's.  The HMI's and Remote I/O all communicated back to the CPU using a private ethernet network. The PLC was connected to the internet for remote troubleshooting or monitoring.

 

The system was installed over 6 weekends, one press per weekend so that we did not halt production. The plc would monitor each set of light curtains on the press for safety, upon the operator loading the press the plc would close a 30" to 36" bore cylinder in less then 30 seconds and confirm the clamping pressure of the press was at the required pressure of 2,000 tons.