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PDA Lends Expertise to Conveyor Controls Project

Process and Data Automation (PDA) provided engineering expertise for a conveyor controls project at a beverage company based in the Great Lakes region. This expertise was directed at the design and implementation of new programming of the OEM and plant provided PLC, HMI and motor controls in order to integrate the plant’s existing processing systems and conveyors into a new line configuration with OEM controls. The client requested that the motors be controlled by new Allen-Bradley Power Flex 525 Series VFDs communicating via ethernet, within new control panels designed and built by Krones Inc.

The engineering group at PDA provided the labor necessary to write the controls code that was integrated with the PLC supplied by Krones. While the PLC and HMI code was what the project required, what was necessary was this and additional, engineering for the final design and project administration to incorporate the needs of both client and OEM.

The project was organized for PDA to provide engineering to coordinate and control the existing conveyor and machine centers that were necessary for the operation of the bottling line, and where the existing centers had not been upgraded. This involved blending equipment from multiple manufacturers into a functioning system, coordinating installation, start-up and runout testing between multiple trades. In addition, PDA acted as a resource to both the equipment supplier and the end-client to triage and resolve issues that were outside the scope of one single party. This role was essential in this project because PDA acted as the glue or connection between the new machine centers provided by Krones, and the original hardware installed in the plant. The involvement of PDA allowed the other parties to focus on their core responsibilities.

The solution provided by PDA has led to increased throughput, a more modular system, and reduced project costs. The integration of the OEE data from the machine centers into the line information system (LIS) now allows data to be readily obtained or tracked by the end-client.

Future upgrades the end client is considering are:

  • Line Balancing
  • Control Zoning (currently there is only one zone)
  • Line Diagnostics LD
  • Line Management Systems LMS

 

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