Posted by Scott Alter on Wed, Feb 22, 2012 @ 10:47 AM
Primary System’s Inc. is proud to help save lives!
Our control systems engineers have collaborated with Luciano Packaging Technologies and Faber Industrial technologies on a project that will result in a completely unique, automated combination vaccine packaging unit for the end customer, Crucell. The unit is capable of sorting, packaging, analyzing, and preparing 150 single-dose vaccines a minute. Currently, this process is done by hand and is only producing about 25 vaccines a minute in South Korea where the unit has been shipped. As stated on their website, the “Quinvaxem uniject vaccine” is a:
Fully liquid
pentavalent (five-in-one) vaccine (that) protects infants against five deadly childhood infections: diphtheria (D), tetanus (T), pertussis (P, whooping cough), hepatitis B (HepB), and Haemophilus influenzae type b (Hib). Combination vaccines help to simplify and harmonize vaccination schedules, leading to increased vaccine coverage and greater cost effectiveness…an ideal choice for protecting babies in developing countries with infrastructure and hygiene problems. (http://www.crucell.com/Products-Quinvaxem). 
Included in the two synchronized machines are:
- Siemens PLCs
- Siemens motion servos
- Allen Bradley PLCs
- Sick Safety Controller
- Accraply Labelers (3)
- Kepware OPC Server (For modbus, Allen Bradley, and Custom communication)
- Adept Robots (2)
- Dalsa Vision hardware (including 15 camera) and software (programmed by Faber Inc.) (www.faberinc.com)
- Networks include:
- Profibus
- Ethernet IP
- RS 232 over Ethernet encapsulation
- Modbus TCP
If you would like to learn more specifics about this project, the hardware used, or what PSI can do for you, please click the button below.
Posted by Scott Alter on Wed, Dec 07, 2011 @ 01:49 PM
Yaskawa VFD-based Liquid Delivery Pump System
Main advantages for our customer:
- Full featured, Yaskawa A1000 VFDs means implementation with lower investment.
- Ease of communications with Rockwell Allen-Bradly CompactLogix PLC means quick configuration to meet a short delivery requirement.
- On-site and remote access of the system means continuous operations.
- More production and less downtime, meaning higher profits for our customer.
Recently, PSI helped one of the our customers implement a 3-color liquid pump system that continues to successfully fill twelve separate holding tanks directly from tankers utilizing Yaskawa A1000 Variable Frequency Drives (VFD) for flow control. The A1000 is a full featured drive, providing outstanding quality, performance, flexibility, and environmental friendliness through 1000HP. We at PSI chose the drive because of its reliability, availability, competitive price, and support of a variety of communication options. Our engineers also like the convenience of SIL3-rated inputs for emergency stop capability.
We were able to quickly and effectively set up an easy to use system that has continued to perform at a desired level. In addition to the on-site functionality, the Yaskawa A1000 drive allows us to remotely control and monitor the system from our office.
The drives are being controlled by a Rockwell’s Allen-Bradley CompactLogix Programmable Logic Controller (PLC). The PLC and VFD used for this job work seamlessly together. It is this tight integration between programmable software and controller modules along with the reliable hardware that help reduce the cost of normal operation for our client.
Products used for job:
-Yaskawa A1000 VFD
-Rockwell (Allen Bradley) CompactLogix PLC
-Automation Direct C-more Operator Interface Touch panel
Posted by Scott Alter on Tue, Jul 26, 2011 @ 07:52 AM
Web-based HMI using Automations's "Ignition"
Primary Systems, Inc has found Inductive Automation’s Ignition HMI to be a package incorporating new technologies into the automation process. The benefits it has brought to our customers include:
- Web-based package runs on a central server. This means only one place to administer the software, even with multiple users.
- Ease of adding users. A client does not need to have an expensive view package – only a conventional web browser and Java. This means to add another node only means giving that user a password.
- Unlimited number of users. Adding one or 10 more clients means zero additional software cost.
- Unlimited number of “assets”. Whether monitoring and controlling one PLC or dozens, the same software package, with the same cost, will accomplish what needs to be done.
- SQL database. This means it is very easy to interface with other systems.
- Ease of integration with other systems.
This architure opens possibilities anavailable with convention systems. Please contact PSI with possible applications.
Posted by Scott Alter on Wed, Feb 16, 2011 @ 01:40 PM
Yaskawa MP2300 Servo Motion Controller system
PSI’s use of Yaskawa motion control systems has been very positive. In particular, the servo systems have shown the following benefits:
Auto Discovery:
- When powering a system for initial setup, the software goes on the network to find all motors/servos. This eliminates one area of delay.
- The software also finds the part number for the motor from the encoder on the motor.
- PSI has found the servos “tuned” right out of the box.
Native/On-Board Ethernet:
The motion controllers have built-in Ethernet ports. This means there is no need to buy an expensive separate Ethernet communications module. In particular, the MP2300 sixteen axis motion controller does not need the following separate items, which means a significant savings in hardware purchases:
- Rack
- CPU
- Power supply
- Ethernet Module
- Sercos Module
Capabilities beyond motion control:
PSI has found that the MP2300 controller has the ability to control processes like a process controller with the addition of I/O.
Multitasking:
The controller has the ability to set different scan rates for different components. This means different priorities can be given to different functions, allowing the exact level of control for each element.
In summary, PSI finds the capabilities of the Yaskawa servo motion control systems every bit as good as competing systems, while enabling a significant savings in hardware investment.
Posted by Scott Alter on Fri, Jan 14, 2011 @ 10:58 AM
New Micro 800 PLC. Allen-Bradley released a new “tiny” PLC. A very small PLC deserves some very brief bullet points:
- Main reason for existence – it costs less than $100
- A “bunch” of expansion modules. Bunch is the word from Allen Bradley.
- This has its own software package – not any RS Logix that programs your MicroLogix or ContorlLogix PLCs.
Don’t make the mistake I made. This is NOT a MicroLogix PLC. It is a very low end unit.
It looks like you need to have all of the following reasons to choose this unit:
- Replace a few relays
- Extremely cost sensitive
- Never any chance of needing more functionality
- You want to see Allen-Bradley’s nameplate on everything.
If you need all 4 of the above features, the Micro 800 may do the job.
When you are looking for something in the very low cost area can’t say yes to all 4 bullet points above, there are options outside the Allen-Bradley product line that give you more functionality. Feel free to call me or email me and we could recommend the appropriate hardware and software.
If you would like more information on the Micro 800 PLC, or perhaps inquire about a job that PSI can help you with, please contact us at 732-679-2200 or click here: 
Posted by Scott Alter on Wed, Dec 15, 2010 @ 12:33 PM
Two Ethernet ports on Allen-Bradley PLC CPUs. Many of Rockwell’s new products are coming with TWO Ethernet ports. This has several advantages to users:
- Easy layout for an Ethernet “Ring”. Multiple PLCs can be “daisy-chained” to give a Ring layout. If the Ethernet cable is severed, theoretically there is a second path to allow communications. While not a fully redundant network, it is an inexpensive way to get most of the way there.
- Ethernet IP for motion control. Rockwell is now promoting the use of their Ethernet protocol for motion control. This means that the second Ethernet port can be available for communications directly to a VFD if desired.
- Separtate switch is not needed. For simple systems such as one PLC and one HMI, the second port eliminates the need for a separate switch. Usually you would add a switch to this two node system so you can plug a laptop or other device in for troubleshooting, or to connect to some larger network. That is included in the unit.
There is of course a trade-off. With this arrangement you have one expensive CPU instead of an expensive CPU and an inexpensive switch. If the separate inexpensive switch fails, you can replace only that. If the switch that is internal to the CPU fails, then you need to replace the CPU. When you decide on eliminating a separate switch, you must balance this concern against the advantages listed above.
Posted by Scott Alter on Mon, Nov 22, 2010 @ 04:49 PM
This posting’s Content:
- The Automation Fair
- Redunant I/O
Next posting’s content:
- Two Ethernet ports, Ethernet Rings and Allen-Bradley
The Rockwell Automation Fair is one of the best places to see what the automation industry is “thinking”.
My goal in attending Automation Fair 2010 was to provide our clients an unbiased opinion of new hardware, software, and services available to the manufacturing industry. Our customers have found it very refreshing to hear from someone without an Allen-Bradley point of view which is what I will be doing here.
Each blog posting will highlight one specific area that I hope you find enlightening. Please check the blog routinely to see added postings.
Redundancy. There are two new items that Allen-Bradley is featuring related to control systems redundancy:
- Redundant I/O:
- Ethernet rings:
Allen-Bradley has a good proven architecture for redundant PLCs with their ControlLogix platform. More discussion on this in a future posting.
Whenever you consider the need for redundancy, there are always multiple points of possible failure that could be catastrophic to the system. In this case, Rockwell is addressing two more of these points:
Redundant I/O, named “High Availablility”: Picture an Ethernet cable (communicating via Ethernet IP) coming from a ControlLogix CPU to this new I/O cluster. Lets assume you would normally have a 16-point discrete input module. In this case you would have two input modules that act redundantly.
During normal operations, the first discrete module is functioning. If it fails, the second module picks up functioning in a seamless manner.
The same functioning occurs for all conventional type I/O modules;
- Discrete output
- Analog input
- Analog output
You also have the flexibility to mix and match in the same cluster. For example, you could have redundant discrete input modules, while at the same time have a non-redundant analog input module.
If you want our opinion if this would be cost effective in your application, contact me at salter@primarysys.com