Technologies: Siemens 1500 series PLC WinCC Comfort Pro HMI Bosh Conveyance and Pallet Stops Simatic MV530 2D Barcode Scanner Siemens G115D VFD Background: A large industrial equipment manufacturer had an existing, mostly manually operated, production line to build and test high-power breakers. The assembly line was mostly manual and required operators to know where the

Technologies: Tube-based Model Predictive Control (TMPC) Linear Temporal Logic (LTL) Specifications Optimization Python 3 Summary: An R&D startup under a major tech company, that aims to remove carbon emissions from the environment, built a system to extract carbon dioxide from the atmosphere. To ensure the constant flow of the CO2-adsorbing material in the system, we

Technologies Ignition Perspective 8.1 by Inductive Automation MQTT using Cirrus Link MQTT Ignition modules Modbus TCP and Modbus RTU Schneider Electric PLCs SQL databases Summary A client required a Data Center SCADA system to monitor and control multiple data halls, system alarming, redundancy, and data collection for a new

Technologies: Beckhoff TwinCAT 3 TwinSAFE PLC Visualization Beckhoff AX5000 Drives 3 Axis gantry Beckhoff AL8000 Linear Motors Keyence CL-3000 confocal displacement sensor Trumpf laser with EtherCAT comms Background: A major EV manufacturing company developed a novel clamping device to hold EV battery cells in position for welding the current collector in place. An OEM had

Technologies: Allen-Bradley ControlLogix Inductive Automation Ignition 7.9 Modbus TCP RTA Ethernet/IP to Modbus RTU gateway Background: A leader in indoor vertical farming custom designed a PCB to control the brightness of 14' grow lights. The PCBs were to communicate with the Allen-Bradley ControlLogix PLC via Modbus RTU through an RTA gateway. Two systems consisted

Technologies: Unitronics Unistream PLC and HMI Unitronics Unilogic Allen-Bradley Kinetix 500 servo drives Microsoft VB .NET TCP/IP Communication GigE Cameras Background: A major aerospace manufacturer has an automated materials testing system which was programmed by the original equipment manufacturer utilizing a Unitronics Unistream PLC. However, the system had many programming issues that were preventing

Technologies: Beckhoff CP6606 Beckhoff TwinCAT 3 Beckhoff PLC HMI Modbus Communication TCP/IP Communication Background: Client manufactures UV curing systems with a huge range of option and configurations revolving around one central system. The client previously employed a full-time engineer to create a program to fit the specific options of every machine sold. This was

Studmeister had a custom roll forming machine which creates custom parts based on CAD recipe files. The machine was running on an outdated Mitsubishi PLC with a Microsoft .NET PC based user interface. The motherboard stopped working and replacements were no longer available. Source code for the machine and CAD recipe decoding was not available either.