Controls Design Applications

Our expertise spans a wide range of automation applications including Packaging, Die casting, Gantry systems, Assembly Machines, Body-In-White Automotive lines, Press Automation, Laser Cutting and Welding and Glass insertion.

Hardware and Software Design of Automated Control Systems

  • Electrical, Fluids and Panel designs.
  • Bill of Materials.
  • Safety requirements (Operator and Robots).
  • PLC and Safety PLC program development.
  • PC Based Controls design and programming.
  • HMI programming and screen development.

Kits and Retro Fits

  • Hardware and Software process improvements or product updates.

Safety

  • Design and review systems to ensure they are in accordance with industry standards such as; RIA, ANSI, NEC/NFPA.

Project Management

  • Design follow-up
  • Schedule management
  • Material procurement.
  • Build follow-up

Onsite Services

  • Start-up/Debug.
  • Installation Supervision.
  • Production support.
  • Cycle time and throughput analysis.
  • Skilled trades training.

Application Examples

Welding and Material Handling Controls Engineering

The following robotic workcell is controlled with the following components:

Allen Bradley Control Logix Processor
Allen Bradley Guard Logix Safety Processor
Allen Bradley Panelview Plus running RS View Enterprise

All components (remote IO, Robot controllers, sealers) communicate via Device Net. All Processors communicate to one another via Ethernet. Every system is controlled by two processors; One Control Logix  Processor to handle all of the process functions, and one Guard Logix Safety Processor to handle all of the safeties for the system. The Guard Logix Processor replaces all of the hardwired safeties devices with a logic driven safety program.

Available Videos ↓
Welding and Material Handling Control Systems

In this video, the robot picks up parts from an operator load nest (already completed). Once the robot has the parts, the robot slides its 7th axis to a sealer/adhesive station. While the robot is running through the sealer application, in the background you can see an 8 axis robot traveling down its 7th axis and loading the tool with the part. After all the parts are loaded into the tool, the tool travels down the 8th axis to the weld position where all the parts are welded together.

Robotic Vision Based Material Handling

This robotic workcell is controlled with the following components:

Allen Bradley PLC5
Cutler Hammer Panelmate HMI
ABB Robot
ABB TrueView 3D Vision components.

The PLC monitors the safeties and the part racks. When a rack is loaded into the cell, The PLC commands the robot to start its pickup routine for that rack. Each rack has several parts in it, so the robot starts at on side and searches for a part. The robot approaches the part and positions the camera for the vision system above the part and triggers the vision system. The camera takes a picture and the vision system determines if there is a part there, and in what (of 8) orientation the part is in. It then gives the robot the coordinates of the part allowing the robot to pick up the part. The robot then reorients and picks up the part. After the pickup is complete, the robot waits for the signal to allow it to drop onto the conveyor. Once the drop is complete, the robot will continue to unload the rack. The PLC monitors the position of the rack and once the robot is at the last part, that rack will be flagged for removal, and the robot will begin to unload the other rack.

Available Videos ↓
Robotic Vision and Material Handling Control Systems