Projects

New Systems

12 Station Bulk Bag Filling System

Responsibilities: Electrical design, PLC and HMI programming, commissioning, startup and training

System Description: Control system for filling bulk bags with rubber pellets. Each station fills a suspended bulk bag to the target weight (3000 lb), lowers the full bag onto a shared conveyor line, and conveys the bags to an unloading station where fork lifts remove the bag. Two identical control systems were used for redundancy on this continuous production line. The system included Allen Bradley PLCs and HMIs, limit switches, pneumatic actuators, hydraulic pumps and cylinders, load cells, blowers, metal detectors, conveyors, and photo eyes. Communication with upstream equipment was implemented during startup.

Concrete Slurry Batch Controller

Responsibilities: Electrical design, scale controller programming, commissioning, startup and training

System Description: Concrete slurry batch plant upgraded from manual controls to a fully automated system with data logging for compliance. The Rice Lake scale controller operates valves, mixers, conveyors, and pumps to fill, mix and discharge the slurry to a holding tank. Each ingredient's weight, batch weight, and totalized weight are logged to an internal database accessed by a PC on site. Wireless level transmitters and pump speed controls were also developed for the project.

PH Probe Cleaning Controller

Responsibilities: Electrical design, pneumatic design, PLC and HMI programming

System Description: 6 self-cleaning PH probes needed to be cleaned continuously on a schedule. This system allowed user programmed cleaning schedules to run on a loop while also allowing manual probe cleaning per operator intervention. Utilized Allen Bradley PLC and Automation Direct HMI. Field equipment: pneumatic solenoids and, ASCO water valves.

More

Crane Location Monitoring

Crane Overload Monitoring

Waste Trailer Remote Monitoring

Scale kiosks

System Upgrades

Powder Mixing and Drum Filling System Upgrade

Responsibilities: Electrical design, PLC and HMI programming, commissioning, startup and training

System Description: An existing powder mixing and drum filling system in a Class 2 Div 1 location was undergoing an upgrade to the drum filling station to incorporate a scale for weight-based filling. At the same time it was decided to upgrade the legacy Allen Bradley PLC and incorporate an HMI. Field equipment controlled includes: motors, pneumatic actuators, load cells, motor brake, level sensors, rotary airlock (VFD controlled), and

Gas Cylinder Filling System

Responsibilities: Program update, commissioning, startup and training

System Description: Concrete slurry batch plant upgraded from manual controls to a fully automated system with data logging for compliance. The Rice Lake scale controller operates valves, mixers, conveyors, and pumps to fill, mix and discharge the slurry to a holding tank. Each ingredient's weight, batch weight, and totalized weight are logged to an internal database accessed by a PC on site. Wireless level transmitters and pump speed controls were also developed for the project.

Troubleshooting and Repairs

Furnace Controls

Summary: PLC and Electrical troubleshooting for an industrial gas furnace that failed to start. After seeing no alarms of faults, a short was found on melted field wiring causing momentary power loss and automated sequence interruption.

Furnace Controls

Summary: PLC and Electrical troubleshooting for an industrial gas furnace that failed to start. After seeing no alarms of faults, a short was found on melted field wiring causing momentary power loss and automated sequence interruption.