Automated Vials Plate Loader

Location: Coralville, Iowa 52241, USA

Industry: Manufacturing industries (including automobile, cement, textile, steel, glass, wind turbine etc), Robotic automation

Business Functions:

  • Engineering
  • Quality Assurance
  • Manufacturing

Problems

The client was looking forward to enhancing their existing automation system for loading the plates following the best / benchmark industrial practices. The main challenges with their system included the following:

  • Unavailability of all the relevant I/O’s data to be exchanged with other software
  • Invisibility of important alerts
  • Missing PackML states
  • Inability to access cause of process failure due to absence of error logging
  • Missing safety features leading to potential serious injuries

Solutions

Allied worked to provide the following solutions to:

  • Capture the relevant I/O’s data and variables to ensure their availability on ADS for external use
  • Operationalize the important alerts
  • Implement the missing PackML states
  • Log the errors
  • Implement the machine safety features

Benefits / Results:

  • I/O’s and machine relevant data is accessible for analyses
  • Alerts are operational to improve the Automation process
  • PackML states
  • operational consistency
  • Standard defined machine states and operational flow
  • Overall Equipment Efficiency (OEE) data
  • Root Cause Analyses (RCA) data
  • Following the error logs, one can pinpoint the cause of process failure
  • Virtually no safety hazard

Beckhoff PLC

  • Open, PC-based control technology

TwinCat

  • Used structured text for PLC programming

Banner XS26

  • Safety controller used for implementing the safety features

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