Monthly Archives: February 2020

PLC Training Oklahoma City — April 7 & 8

Posted February 19, 2020 by Pepper Hastings

Categories: Blog, Training Class

Two-day class on basic and intermediate PLC.

Plus you'll leave with $230+ worth of hard equipment, including a leather engineer's bag. This is a HOT class -- Hands On Training -- that will add value to your skill set. Invest in yourself and your career with training from Innovative-IDM.

$449 for both days. Email info@iidm.com to reserve your spot. Class limited to 12 seats. Laptop required. Hearty lunch included. Executive Residency, 4750 S. I-35 Service Rd, OKC, 73129

Best Western Executive Residency, 4750 S. I-35 Service Rd, OKC, 73129

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Hydraulic Presses Improved with PLC and HMI

Posted by Pepper Hastings

Categories: Blog

Overview:

A plastics manufacturer suffering from poor productivity, inefficiency and a large number of operator errors acquires an automated solution to alleviate the problem. Using a simple setup with an Omron PLC and Omron HMI, the manufacturer reduces wasted time and material and utilizes his hydraulic presses to their full potential.

The Challenge:

The process in question was a fully manual process. It consisted of an operator filling a mold with resin, setting the pressure, and activating the hydraulic press. The operator would wait for a given time as indicated in the “recipe”, then increase the pressure setting. The operator, again, would wait for a given time, and then disengage the hydraulic press. The mold is flipped over, and the process repeated. The total time of production for one part could run from 30 minutes to 300 minutes, depending on the resin composition and size of the finished product.

This type of process, while simple in nature, is actually inherently prone to productivity issues. The process relies completely on the operator to accurately set and control variables, such as pressure and pressing time. Human error, and unfortunately a lack of care by the operator, was resulting in these variables being inaccurate and ultimately many parts were rendered useless. On a typical day, the manufacturer had 10 presses running and was losing two parts a day due to operator error, at an average of $175 per part.

The Solution:

Our solution was to automate the process by installing an Omron CP1H PLC and an Omron NS series Industrial Touch Screen HMI on each press. The operator from then on would only need to select the “recipe” from a user friendly menu on the HMI, and press start. The PLC from then on would control the process by starting the hydraulic press, setting the pressure required, and time to hold. It would alert the operator when the process was completed, either to flip the part over or to remove the product. It also would trigger an alarm if a mechanical failure had occurred in the press and the set pressure could not be achieved.

The total cost for setting up the system, allowing for programming, hardware, and installation was $130,000.

 

The Results:

The manufacturer eliminated the losses due to defective products coming out of the presses. While that alone would have covered the cost of the automated solution in approximately one year and directly increase his revenue by $127,750/yr from then on, there were also added benefits that became apparent. Productivity was increased as now a visual alarm allowed the supervisor to quickly see when a press was sitting idle, and the situation corrected immediately. The solution provided also reduced the manpower required to run the ten presses from five operators to two.

Materials Used:

OMRON CP1H Series PLC with Ethernet Interface.

OMRON NS Series Industrial Touch Screen HMI, 8” with Ethernet Interface

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Application Note: Going from DC Motors to a Synchronized System of AC Motors and Drives

Posted February 12, 2020 by Pepper Hastings

Categories: Blog

Overview:  At one company, there is what they call a brine box. There is a saltwater tank setup that slows an electric motor saw. Within this setup, they use three DC motors. They decided they would like to change the DC motors to AC motors. In addition to changing from DC to AC, they would like to implement speed control between the motors, including the ability to decelerate the motors at the same time and at the same rate.

The Solution: We selected the AC motors to match the required speed and torque needed for the application. This information was obtained by analyzing the load conditions and from the specifications at which the DC motors were running the application. For speed control, the simple solution was to daisy chain Yaskawa drives. This allowed the drives to communicate with each other, as well as synchronize their deceleration.

The Results:  The AC motors can be rated to give the same performance, or higher performance, as the DC motors.The AC drives can provide for controlled acceleration and deceleration rates. Connection between the drives allows for the synchronization of the acceleration and deceleration rates.The Yaskawa drives have the ability for the parameter setting to be extracted. This would make programming the drives to be easier by setting the parameters in one, and just copying the parameters from that one to the other two.

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Omron PLC Training Tulsa – March 10-11

Posted February 11, 2020 by Pepper Hastings

Categories: Uncategorized

Two-day class on basic and intermediate PLC.

Plus you'll leave with $230+ worth of hard equipment, including a leather engineer's bag. This is a HOT class -- Hands On Training -- that will add value to your skill set. Invest in yourself and your career with training from Innovative-IDM.

$449 for both days. Email info@iidm.com to reserve your spot. Class limited to 12 seats. Laptop required. Hearty lunch included.

 

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