Case Studies
REAL PROJECTS | PRACTICAL SOLUTIONS | MEASURABLE RESULTS
Garage Door Formation
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Legacy HMI RSView32 system to Ignition SCADA Modernisation
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Enabling remote connections and access to site PLC programs and Ignition projects for support and troubleshooting.
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Implemented graphical representations of equipment and processes, with animations in Ignition to help operators visualise plant operation.
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Resolved persistent production issues via PLC coding, including problems that had continued for more than 10 years, delivering lasting improvements to plant operation.
Recipe Management: Implemented recipe management to support production setup and process control.
Automatic Downtime Recording: Developed functionality that automatically calculates downtime duration and displays it in an Ignition popup, allowing operators to enter the reason for the stoppage.
Quality-Control Workflows: Implemented automatic quality-check triggers in Ignition that notify operators when a check is due and require them to complete the check and enter results. Quality-check data is recorded in a database for review and traceability.
All implemented using Python coding in Ignition
Ignition SCADA and MES Functionality
Graphical Visualisation: Clear operator interfaces, meaningful alarms, trends and reporting. New applications and upgrades tailored to your plant.
Production Reporting and Efficiency: Production numbers, trends and charts in Ignition give managers visibility of output and operating efficiency, helping them monitor performance and identify opportunities for improvement.
Ignition SCADA:Python coding snippet
Glencore Mine
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Independently completed the full PLC and HMI programming across multiple PLCs for a new 5 km line incorporating 1,000 kW motors, within an overall project valued at $300 million. The PLC and HMI software brought the automated process to life, coordinating equipment, sequences and operator control across the production line.
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Implemented PLC-to-PLC communications with real-time data synchronisation, enabling multiple PLCs across the line to operate together as one coordinated control system.
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Actively involved in commissioning and testing, including functional testing, sequence verification, fault finding and supporting the line through start-up to achieve reliable automated operation.
CSR Gyprock
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Programmed the PLC and HMI for a new process line incorporating
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conveyors,
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trippers,
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vibratory screens,
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diverters,
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silos,
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stockpiles and
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associated equipment.
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Developed HMI displays focused on situational awareness to help operators understand process conditions and equipment status.
Space Bound Vehicle Flight Computer
View from one of the launched space vehicles
Several space vehicle flight computers were completed, which Guided, Navigated and Controlled (GNC) the space vehicles to space successfully upon launch. The flight computers consisted of:
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System On Chip (SOC) - Multi Core with FPGA (Xilinx)
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Real Time Operating System and Scheduler
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FPGA VHDL Firmware Design - including communication protocols such as UART, HDLC, IIC and SPI
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Board Support Package, Driver and Application Level code development
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Space Vehicle Avionic Components
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Triple Mode Redundancy (TMR) and Single Event Upsets (SEU) handling
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Algorithm
Robot Welding Systems
Robot with a welding head
Robots were programmed and integrated into a PLC system that implemented spot welding on several fixtures for the car industry. The system included:
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Hardware design of the system.
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Program Safety PLC (Siemens TIA Portal) for machinery and robot operations including:
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Robot and its components
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Weld Timers (medium frequency inverters)
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Fixtures and valve banks
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Safety program
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Human Machine Interface (HMI)
Coal Handling System
A view of conveyor, tripper and stockpile
Coal was delivered using a conveying system and tripper to a stockpile and a reclaim conveying system from this stockpile to a train loadout system.
The system consisted of:
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PLC (Allen Bradley) for machinery operations and automatic sequences
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Conveyors
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Sump Pumps
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Tripper
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VSD drives and motion controls.
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Citect SCADA and HMI
Cement Factory Slag Feed Integration
Cement factory
A slag feed line was integrated into the already operating cement factory.
The system consisted of:
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PLC (Siemens)
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Conveyors
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VSD drives
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Digital and Analog Inputs and outputs
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Citect SCADA
Ultra Pure Water Treatment / Reverse Osmosis
One of the HMI pages
Ultra Pure Water (15Mohms) was to be created and supplied for washing of electronic material and chemistry.
The system included:
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Design MCC switchgear PLC panels (electrical drawings).
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PLC (Siemens)
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Pumps
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Valves
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VSD drives
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Digital and Analog Inputs and outputs
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HMI
A generator used in the power station
Power Station
Power station monitors the gas cost prices and when it is below threshold, the generators will turn on to produce power. Power station can be controlled and monitored remotely in any location in the world.
The system included:
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PLC (Schneider)
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CitectSCADA where its function is to provide operating information, advanced controls and setpoints to the operators. CitectSCADA was to communicate (read/write) with a remote database (Cicode). The SCADA was to export all relevant data to the database such as produced power and at the same time read from the database the generator operation commands. This remote database can be accessed anywhere around the world, even using a mobile phone, to monitor and control the plant.