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.
An industrial utility service company in Kentucky needed to upgrade and migrate its distributed control system (DCS), which came with a few 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.
A steel manufacturer that needed two impellers repaired found a solution through reverse engineering that was faster and more cost-effective.
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.
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.
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.
Cover Story: System integrator upgrades a cherry packaging operation at Prima Frutta, for a 50% production increase, using Ethernet, wireless, and mobility technologies, along with extensive planning and simulation.
Project and product details follow in a major Industrial Automation Group (IAG) and Prima Frutta upgrade to Prima Frutta’s Linden cherry packing facility. Questions and answers cover controllers, sensors, actuators, Ethernet, wireless, timeline, and advice.
Control system migration projects can provide significant value to industrial operations by ensuring a smooth transition to newer technology with virtually no changes to physical wiring or intellectual property.