This machine is at my current job. The infeed roller table is controlled by an a old Automate 15 processor. There were some issues with how the roller table acted. So, I took it upon myself to correct the issues.
The programing software runs under dos and with my tablet running windows 8, that means running another program called DOSBOX in order for this Automate programing software to work. There's no real serial port on this tablet and I couldn't get my USB-to-Serial converter to connect to the Automate. I resorted to learning the programing software on my tablet, then write the program on the old Pentium desktop on a cart to program the Automate.
I have corrected the issues with the infeed table and made some other improvements to reliability of the machine such as stopping the rollers from running after 15 seconds of no product on the table. The operators are much happier that they now a flawless operation. They don't have to go play with the sensors trying to get the table to move. It all works as it was possibly intended. They can now just concentrate on packaging the product to ship, saving them time.
Tuesday, March 25, 2014
RV Bus
My brother's girlfriend had gotten an RV bus and I was asked about updating the controls. I looked into this and started writing a program to control and monitor things like thru water pump, water heater, generator start/stop, inverter on/off, battery voltage, battery amperage, battery level and tank levels.
I got these things to work on the test bench and started working on WiFi access to the plc. WiFi access from any given spot was going to require more hardware so, I dropped that for now.
My brother (Jeff) and his girlfriend (Julie) had taken a vacation to the Grand Canyon. So, I did not get the chance to get anything installed. That gave me time to think about what else could be incorporated into this control system. That's when I thought about and auto-leveling control for the leveling jacks. I ordered some parts and made a leveling sensor plate to be mounted under the bus. I then got started on the programming. After finishing the program, they got back from vacation and decided to move to California. So, still no time to get the system installed. Over the next several weeks, I debugged and studied ways to refine the whole plc code.
I have been thinking of incorporating the environmental thermostat controls. Maybe even main engine and generator temps. Maybe I'll do it after the rest of the system is installed and fine tuned.
Stay tuned...
I got these things to work on the test bench and started working on WiFi access to the plc. WiFi access from any given spot was going to require more hardware so, I dropped that for now.
My brother (Jeff) and his girlfriend (Julie) had taken a vacation to the Grand Canyon. So, I did not get the chance to get anything installed. That gave me time to think about what else could be incorporated into this control system. That's when I thought about and auto-leveling control for the leveling jacks. I ordered some parts and made a leveling sensor plate to be mounted under the bus. I then got started on the programming. After finishing the program, they got back from vacation and decided to move to California. So, still no time to get the system installed. Over the next several weeks, I debugged and studied ways to refine the whole plc code.
I have been thinking of incorporating the environmental thermostat controls. Maybe even main engine and generator temps. Maybe I'll do it after the rest of the system is installed and fine tuned.
Stay tuned...
Sunday, February 16, 2014
Peabody
This machine is at my current employer and had an HMI that was removed at some point before my time. This meant that when the operator needed a particular option changed, it required an electrician to change a value in the plc memory via a pc with the program loaded.
I had talked about installing an HMI to change this option. Not too much time passed and I was told to do it.
I was then on a mission to see what it would take to do this job. The processor is a GE Fanuc Series One. I found that the DirectSoft koyo software was compatable with this. I go connected to it and was not too surprised with the ~100 blank lines of code in the program.
I studied the program after cleaning it up ad adding comments from the 1989 prints that I had found. I got a C-More HMI, that was removed from another machine, got it talking to the GE and setup the screen to change what the operator needed. I also found some error messages that were for the old HMI. I had to modify the plc program to set error numbers for the new HMI to show the same messages.
Now that all of that works, I had to move the HMI from the 'test' area to the operator's console where the old one used to be. Now, all is working just fine and I was able to keep the non-plc guys out of the program. This also frees up the electricians from making these changes every few hours.
Mixer #4
This mixer has had been moved from it's normal production area to a new production line for a whole different product. I was asked to retrofit this mixer like mixer #1.
As I started on this project and had the parts on order, the main voltage had been changed from 480v to 208v. That changes a few things and had to order other parts as the amperage is now going to be higher.
This mixer incorporated all of the previous experience I had with the mixer's operation and controls. The old panel was proprietary and mount to the side of the machine. All wiring still had to come from this spot. Not undoable, just different from the others.
I setup a new panel just like mixer #1 and control software ended being a mix of mixers 1 & 3, but with some aspects just for this mixer.
After debugging and ensuring the new system was working, I spent a few hours training the supervisor, operators, and maintenance personnel on the new controls.
I have had a few calls about this mixer not working, but found that the issues were not controls related, but rather bad motors or chafed wires at the motors. Those issues were repaired by the in-house maintenance dept.
Saturday, February 15, 2014
Multiple Swamp Coolers
After a recent conversation with the co-worker (Mark), he has decided to drop one of the three coolers. Now, I have removed the third cooler from the program. I have added another PID loop to control the second cooler from another thermocouple.
While making other tweaks and bug removals, I have found some things to work better and will do to my swamp cooler program.
Wednesday, February 12, 2014
Swamp Cooler
Back in 2003, I had gotten a swamp cooler and wanted a more automated control system for it, but I was on a very tight budget at the time. I wanted my swamp cooler to behave as a HVAC unit. My cooler is the typical one with the options for the unit selectable from the from panel, 'off', 'pump only', 'low vent', 'hi vent', 'low cool', and 'hi cool'. I started with a thermostatic switch and that worked ok, but it would only turn the cooler on and off, that worked best by leaving the cooler on 'hi cool'. This left the house too cold at night and having the cooler come on at night when you really didn't think it was necessary. I knew how plc's worked and it would be perfect to do what I wanted, but didn't have the money to get what I needed so I could start learning them.
In 2011, I went to a new employer and found a whole new set of challenges. My next move with the plc was when I got my first plc. I played with that thing until I had fell over in my chair. I fell asleep at the 'wheel' multiple times just trying to learn everything I could about it. I started whittling away at a control program for my swamp cooler. This took me longer than most programmers because I was new at it, but determined. I got the cooler working with a time-proportional PID loop that would control low and hi speeds. This worked flawless for the last two seasons.
I had been thinking about what more I could do with this. I was thinking of a 3-phase motor so the air flow could be adjusted by the pid directly and eliminate the time-proportional parts as there would no longer be low and hi speed options. I was scouring the web for a 3-ph motor that would fit in the cooler. I finally found one, but it was $400. A little more than I wanted to spend. But, I just might have to bite the bullet and get it. While I was thinking about this, I was also wondering what else I could control in/on/around the house with this plc. I ran a few wires to the garage door button and wrote some code for opening/closing/venting the garage door based on outside temperature and garage temperature. This was tested last summer with great success. This kept the garage from getting too hot during the hot parts of the day.
One year later, I'm training another co-worker and was telling him about my plc controlled swamp cooler and what that I was wanting to put a 3-ph motor for precise fan control. He lit up saying that is what he needs for his house. He tells me that his old school house is over 5,000 sq.-ft. with three swamp coolers and that he'd like to have the control system that I was building. I got a part list together for him with prices and while I was looking for the motor I had found a year ago, I ran across another one for 1/2 the cost! I was excited. I got to work on a new version of the plc program to include the VFD control. I then found that motor on EBAY for even cheaper. I ordered the motor on eBay and now have it here in my house setup for testing. I'm working out any other bugs before the snow melts so I can get the motor installed and get the real-world testing done.
Now that I have my control program written for the VFD and the 3-ph motor here waiting to be installed, I have started working on the same VFD control program, but for three swamp coolers. I told the co-worker that I would do the program for no charge, but he would have to get the parts to make it work. I would even help him install everything. Then there's training time on the new system.
In 2011, I went to a new employer and found a whole new set of challenges. My next move with the plc was when I got my first plc. I played with that thing until I had fell over in my chair. I fell asleep at the 'wheel' multiple times just trying to learn everything I could about it. I started whittling away at a control program for my swamp cooler. This took me longer than most programmers because I was new at it, but determined. I got the cooler working with a time-proportional PID loop that would control low and hi speeds. This worked flawless for the last two seasons.
I had been thinking about what more I could do with this. I was thinking of a 3-phase motor so the air flow could be adjusted by the pid directly and eliminate the time-proportional parts as there would no longer be low and hi speed options. I was scouring the web for a 3-ph motor that would fit in the cooler. I finally found one, but it was $400. A little more than I wanted to spend. But, I just might have to bite the bullet and get it. While I was thinking about this, I was also wondering what else I could control in/on/around the house with this plc. I ran a few wires to the garage door button and wrote some code for opening/closing/venting the garage door based on outside temperature and garage temperature. This was tested last summer with great success. This kept the garage from getting too hot during the hot parts of the day.
One year later, I'm training another co-worker and was telling him about my plc controlled swamp cooler and what that I was wanting to put a 3-ph motor for precise fan control. He lit up saying that is what he needs for his house. He tells me that his old school house is over 5,000 sq.-ft. with three swamp coolers and that he'd like to have the control system that I was building. I got a part list together for him with prices and while I was looking for the motor I had found a year ago, I ran across another one for 1/2 the cost! I was excited. I got to work on a new version of the plc program to include the VFD control. I then found that motor on EBAY for even cheaper. I ordered the motor on eBay and now have it here in my house setup for testing. I'm working out any other bugs before the snow melts so I can get the motor installed and get the real-world testing done.
Now that I have my control program written for the VFD and the 3-ph motor here waiting to be installed, I have started working on the same VFD control program, but for three swamp coolers. I told the co-worker that I would do the program for no charge, but he would have to get the parts to make it work. I would even help him install everything. Then there's training time on the new system.
Intro
This is going to be an interesting journey to all you techies out there. I have been dabbling in plc's for quite some time and have had the opportunity to program them starting with my previous employer. The more I learn the different programming software, the more I want to create a fully autonomous robot. One day... maybe.
I have learned a great deal about PC's -- hardware and software. I currently have 4 PC's in the house. 1 desktop, 2 netbooks, 1 tablet. Now running from Windows 7 to 8.1. I also have several Android devices, phones and a tablet.
I would love to control my house from my Galaxy S4, but that will be another day. I do not want to pay for a service that will do it. I will program something on my own, if nothing else, for the experience.
I have learned a great deal about PC's -- hardware and software. I currently have 4 PC's in the house. 1 desktop, 2 netbooks, 1 tablet. Now running from Windows 7 to 8.1. I also have several Android devices, phones and a tablet.
I would love to control my house from my Galaxy S4, but that will be another day. I do not want to pay for a service that will do it. I will program something on my own, if nothing else, for the experience.
Benier Divider
The Bernier Divider was a little more complex only because it has to VFD's in it and the current plc in it was doing just fine, but the VFD's were giving us issues. We wanted to replace the VFD's with a different brand. I presented the options of replacing the VFD's: Ask Bernier to re-program the plc to work the VFDs of our choosing, purchase the programming software for the plc that's currently in the divider, or replace the plc, hmi, and the VFD's of my choosing.
Replacing the plc, hmi, and the VFD's were going to be the best option for us. Only because I wasn't getting any more money for being the resident programmer. We got the parts in for this machine, I spent a good while programming this one to make sure the VFD's were working as they should. The first VFD was the main machine speed and dictated by the HMI. The second VFD speed was a discharge belt and speed was a percentage of the main machine speed with the option to change faster or slower via the hmi.
There was quite a bit of wiring and installation issues, but I got it done in 3 days. I was then on a time clock to debug any issues with this as I had a new job waiting on me. I spent the next two weeks drilling the machine and the operators to make sure they knew the machine and how to operate it. (Even though I kept the look and feel as close to the original as I could.)
I have been back to this plant for various other support reasons and checked in on this machine. All is still doing ok and working as I left it. I did have to replace the hmi due to oil saturation, but it was back in operation with 3 hours.
Replacing the plc, hmi, and the VFD's were going to be the best option for us. Only because I wasn't getting any more money for being the resident programmer. We got the parts in for this machine, I spent a good while programming this one to make sure the VFD's were working as they should. The first VFD was the main machine speed and dictated by the HMI. The second VFD speed was a discharge belt and speed was a percentage of the main machine speed with the option to change faster or slower via the hmi.
There was quite a bit of wiring and installation issues, but I got it done in 3 days. I was then on a time clock to debug any issues with this as I had a new job waiting on me. I spent the next two weeks drilling the machine and the operators to make sure they knew the machine and how to operate it. (Even though I kept the look and feel as close to the original as I could.)
I have been back to this plant for various other support reasons and checked in on this machine. All is still doing ok and working as I left it. I did have to replace the hmi due to oil saturation, but it was back in operation with 3 hours.
Oddy Pan Indexer
The Oddy pan indexer had operator issues. The current hmi was hard to operate and was very cryptic for most people at the plant. I asked to replace it with another hmi and because of the proprietary plc/hmi system it had, this would also require a new plc. It was OK'd and I ordered, install, and programmed the new system to work with this machine. This section of the machine had a new challenge for me, it needed to control two VFD's speed and run commands. The run/stop command was easy as it was setup as discrete outputs. The speed on the other hand was 0-10v analog out via the VFD's own supply. So, setting up the analog card to act as a potentiometers was a little tricky. The first VFD was running the same direction all the time, but changed speed as dictated by the HMI. The second VFD direction was determined by position sensors and the speed was determined by the HMI.
This machine became trickier to program as the second VFD's motor has a shaft-mounted brake that was failing. So, the system was overrunning the last stop sensor quite often. I had to setup more programming tricks to get the motor to stop were it was supposed to stop. This meant running the motor for x time and then slow to a crawl until the sensor is seen. This was the viable solution and told the boss that a new brake is needed because this is not a servo system. And if they wanted a servo system, the cost of the retrofit was going to be MUCH higher than replacing the brake.
Other than the brake issue, we now had less downtime due to operator error.
This machine became trickier to program as the second VFD's motor has a shaft-mounted brake that was failing. So, the system was overrunning the last stop sensor quite often. I had to setup more programming tricks to get the motor to stop were it was supposed to stop. This meant running the motor for x time and then slow to a crawl until the sensor is seen. This was the viable solution and told the boss that a new brake is needed because this is not a servo system. And if they wanted a servo system, the cost of the retrofit was going to be MUCH higher than replacing the brake.
Other than the brake issue, we now had less downtime due to operator error.
Oddy Chunker
We were having issues with the Oddy chunker with some timers getting changed and it would really create a mess with the machine and causing production downtime. I had set the timers correctly several times only to find that they have been changed again. This was a poor design from the manufacturer and I got tired of re-setting the timers back on a bi-daily basis. I grabbed the first plc I had gotten for programming and wrote a quick program to replace the timers. I wired it all in and removed the original timers and corresponding relays. I tweaked the timer values until the machine was running as it was before. I knew this wasn't going to be good enough, but the timer values didn't change anymore. Now, I could focus on bettering the system. I got a few other sensors I needed, mounted, wired, and programmed. After a few more tweaks, the machine doesn't miss a beat and production runs smoother with less downtime.
Mixer #1
I then pressed to retrofit mixer #1 from relay logic to plc control. I had also stated that I was going to replace everything, including the control panel. I was not going to have a bad flower laden contact prevent my new system from running correctly. I insisted on all new parts as it was the only way to guarantee the system was going to be trouble free.
The company let me do it and this time I chose a different plc model and incorporated more options like thermocouples, current sensors, and proximity sensors. It also had more information on the HMI as I was getting better at this plc stuff. After getting this mixer up and running with no issues, I had gone back to mixer #3 to incorporate the better code I had came up with on mixer #1.
The company let me do it and this time I chose a different plc model and incorporated more options like thermocouples, current sensors, and proximity sensors. It also had more information on the HMI as I was getting better at this plc stuff. After getting this mixer up and running with no issues, I had gone back to mixer #3 to incorporate the better code I had came up with on mixer #1.
Mixer #3
In 2007, I had gotten another job that paid better and was able to save up to start getting what I needed. This job tasked me to do a plc control replacement for a mixer (Called Mixer #3) that was having issues. The HMI on it had died, we had gotten another one in and I tried and tried to get that new screen to work with the Mitsubishi plc. I had issues, not really knowing anything about them, I was sure I could get them working. I ran into road block after road block and could not get them working.
One afternoon, I was troubleshooting an issue with mixer #1 and my boss came by to ask what I had found with it. I stated that I hadn't found the issue yet, but let me convert this flour laden relay system with a whole new plc control system. He and his boss were behind me and said to get mixer #3 working first. So, I finished finding and fixing this mixer and talked with the boss on what I will do for mixer #3. I told him that I would need to replace the plc and the hmi as I cannot get the ones we have to work and that I have a system in mind that is cheap and I'll make them work. He asked for a quote and I got a part list w/ prices and totaled them for him. He approved the ordered and I placed the order. I downloaded the manuals for the plc and hmi. I studied like it was finals waiting for the parts to arrive. I caught up with the boss a few days later to tell him that I have a personal goal to get mixer #3 running within 30 days from the day I get the parts. He looked surprised.
I got the parts in and I poured over it until I go it done. It took me 2 weeks from the time I got the parts to getting the machine running. I was still debugging this system for the next several weeks just to make sure I had everything right. I had also continued to work on this program to remove the redundant code that I had put in when I was dripping wet at programming the plc and hmi.
One afternoon, I was troubleshooting an issue with mixer #1 and my boss came by to ask what I had found with it. I stated that I hadn't found the issue yet, but let me convert this flour laden relay system with a whole new plc control system. He and his boss were behind me and said to get mixer #3 working first. So, I finished finding and fixing this mixer and talked with the boss on what I will do for mixer #3. I told him that I would need to replace the plc and the hmi as I cannot get the ones we have to work and that I have a system in mind that is cheap and I'll make them work. He asked for a quote and I got a part list w/ prices and totaled them for him. He approved the ordered and I placed the order. I downloaded the manuals for the plc and hmi. I studied like it was finals waiting for the parts to arrive. I caught up with the boss a few days later to tell him that I have a personal goal to get mixer #3 running within 30 days from the day I get the parts. He looked surprised.
I got the parts in and I poured over it until I go it done. It took me 2 weeks from the time I got the parts to getting the machine running. I was still debugging this system for the next several weeks just to make sure I had everything right. I had also continued to work on this program to remove the redundant code that I had put in when I was dripping wet at programming the plc and hmi.
Subscribe to:
Posts (Atom)