Case Studies
After the male and female snaps have been inserted, the UR5 places the fabric under a vision camera lens for quality inspection and sorts it in either a “good” or “reject” pile. Courtesy: Universal Robots
Case Studies August 15, 2019

Do-it-yourself collaborative robotic project

Case study: Collaborative robots at a thermal wrap manufacturing company deliver a zero-defect rate while doubling production output. Installation, integration and use has been a do-it-yourself (DIY) project.

By Joe Campbell
Figure 2: The moving platen (yellow structure) is visible above the fixed lower bolster of the 2,430-ton Hoesch press. Courtesy: Delta Computer Systems Inc.
Case Studies August 12, 2019

Motion controller gives old presses new life

Case study: Retrofit controller on four hydraulic presses used a new programmable logic controller (PLC) to control the moving platen and the levelling cylinders would be controlled by a new electrohydraulic motion controller.

By Bruce Coons
Figure 1: The PlantFloor24 global operations center at Maverick Technologies uses best practices to work with manufacturers to remotely resolve issues and provide solutions to keep operations up and running 24/7/365. Courtesy: Maverick Technologies
Case Studies March 25, 2019

Managing remote monitoring

Remote management and monitoring applications help keep operations up and running. External remote management and monitoring teams provide specialized operational knowledge to help with automation and control system issues.

By Dawn Lewis and Evan Pederson
Figure 1: Global Controls Solutions LLC (GCS), a system integrator, helped achieve a food supplier’s goal of improved energy efficiency with an industrial Ethernet network, Profinet, to improve overall operational efficiency. One of the control panels for the refrigeration system is shown. Courtesy: Global Controls Solutions (GCS)
Case Studies February 2, 2019

Profinet network, control system upgrade helps reduce energy costs

A system integrator deployed a Profinet industrial Ethernet network and programmable logic controllers (PLCs) for a food supplier looking to expand its facility. The integrator used the Ethernet network to improve communications and optimize operational efficiency for $125,000 in annual energy savings.

By Nelly Ayllon Lazo
DTE Calvert City (DTECC) in Kentucky chose Cross Company to migrate the APACS DCS to a full Siemens PCS 7 system implementation. Courtesy: Siemens Industry Inc.
Case Studies January 30, 2019

Case study: DCS migration challenges and obstacles for process manufacturer

An industrial utility service company in Kentucky needed to upgrade and migrate its distributed control system (DCS), which came with a few challenges.

By Josh Dalzell
Case Studies August 21, 2017

Robots solve assembly line production challenges

Inside Machines: An electronics manufacturer with double-digit product rejection rates used a collaborative robot that was controlled and monitored in a cloud-connected system to handle soldering, drilling, silicone dispensing, and light assembly. This helped rejects fall to near zero and increased production efficiency almost fivefold.

By Brian Dillman
The steel industry is under increasing pressure to minimize running costs and one manufacturer in Brazil was able to repair two impellers through reverse engineering. Courtesy: Sulzer
Case Studies April 19, 2017

Reverse engineering reduced repair time, costs for steel manufacturer

A steel manufacturer that needed two impellers repaired found a solution through reverse engineering that was faster and more cost-effective.

By Rafael Ribeiro
Total project savings for using a Profinet-based industrial Ethernet system rather than hard wiring was $106,654, said Mike Prokop, CMSE, LSO (certified machinery safety expert, laser safety officer) and chief electrical engineer with Taylor Winfield Tech
Case Studies April 12, 2017

Ethernet cuts automation hardware, labor costs, errors

Think Again about digital networks: A redesigned automated industrial process with the goal of improving safety and efficiency saved $106,654 in hardware, design, and installation costs by using an industrial Ethernet protocol instead of hard wiring, not counting a two-thirds reduction in potential errors or other project benefits.

By Mark T. Hoske
The travelling batcher drive is designed for unloading the batch into each load out silo. Courtesy: Yaskawa America Inc.
Case Studies April 7, 2017

Matrix drives reduce energy consumption for transporter system

Inside Machines: Industrial matrix drives were used for a transporter system retrofit to reduce energy consumption and costs by creating a more maintenance-free mechanically integral distribution system. New system regeneration capabilities for two motors saves an estimated $1,500 per year.

By Mike Grant
Figure 3: Inside the control panel: Each test stand is controlled via a PLC (center left) and a Delta Computer Systems RMC75P motion controller (center right). The PLC and motion controller are connected via Profibus (the purple cable).
Case Studies December 4, 2016

Controller for crane testing

Inside Machines, hydraulic control: Verifying load parameters when testing mobile cranes is important to verify quality, which matters for functionality and safety. New testing systems included installing new proportional servo valves and high-performance, electro-hydraulic motion controllers.

By Richard Meyerhoefer