System Integrator Corner
(Issue 16, 2010)
Ai Control Systems
By Douglas Albright,
Ai Control Systems
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Since its inception in 1985, Ai Control Systems has earned a reputation for excellence and versatility as a Control System Integrator. They offer clients total solutions for their factory automation needs by providing ways to improve productivity, quality, reliability, maintenance, record keeping, and profit margins.
As an integrator, Ai Control Systems is an independent value-added engineering organization which focuses on industrial control and information systems, manufacturing execution systems, and plant automation requiring application knowledge and technical expertise in design, implementation, installation, commissioning, and support.
Ai Control Systems ideally serves customers looking for integration services in a tight timeframe with less than exacting requirements specified. Their agile approach to project methodology allows them to turn around projects in short time frames while adjusting for changes and discoveries during the project. With 25-plus years in control systems integration, Ai Control Systems has learned how to quote projects based on general requirements such as IO count and HMI screen elements.
Typical projects range between $20,000 and $350,000 and their lean approach typically allows for the designing engineer to be present for the assembly, testing, installation and startup of the project. In-house panel assembly and machine wiring also lends itself to this approach.
An example of a project using AutomationDirect products is a slitter line recently completed for a metals finisher. This line had to compensate for variations in thickness of metal sheets, as it cuts a roll of metal into smaller ribbon-like strips. Because the edges tend to be thinner than the middle, the strips of material can vary in length. A pit is used to allow for the increased difference in length as the roll is processed by the equipment on the line. The finished product is small-width reels of material to be used for other manufacturing purposes.
The existing machine’s controls, dating back the 1980’s, were a European PLC and drives, none of which were supportable. When the PLC processor finally failed, the only option was to replace the entire PLC system.
Ai assigned a two-person team to the project, including a senior project engineer and a junior engineer. The first challenge was to get up to speed on the operation and control requirements of the machinery. Next, Ai had to review and validate any work already completed and make changes where necessary.
They chose AutomationDirect’s DL405 PLC, along with a 15-inch C-more operator interface panel, to control the tension and speed of the line, instead of using the smart drives the customer had provided. This decision allows more flexibility for replacements when the drives are past their design life.
The final challenge was to complete the PLC and C-more HMI programming, start up the system and verify its operation. AutomationDirect’s DirectSOFT PLC programming tools, such as the I-Box instruction set and HSC Workbench configuration aids, were used extensively to speed development of the drive algorithms.
Ai’s team worked closely with the client to assure the final application covered all operational requirements.
The project was completed in less than a month and production began with minor startup issues. Callback issues were minor, and because of Ai’s close proximity to the client, could be handled quickly.
This typical application showcases Ai Controls’ ability to accomplish control projects which may overwhelm the customer’s resources, without driving costs beyond their budgets.
Learn more about Ai Controls and this project at www.aicontrols.com.
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