Fast Automation was awarded a contract to upgrade a burner control system. Tuning of the PID loop was a challenge with a large number of variants at play. The new system utilised Allen Bradley’s Compact Logix PLC and Panelview Plus HMI. This Large Snackfood company rewarded the team members with a hearty selection of Snacks!
Fast Automation was engaged to develop a generic filling system to be deployed to previous and new filling sites. Having developed over 30 Gas Filling systems in the past Fast Automation was well qualified to undertake this challenge. The main challenge with this project was flexibility. The end result was a system that allows selection of the following features from the SCADA screens and the automatic enabling of hardware and changing of accessible features and mimic’s to suit. The systems have the following features and options:
The first system was commissioned in Brisbane and a further 3 systems are being commissioned in the next wave October 2013 at time of print.`
Fast Automation has automated several dual 45 Pallet dispensers for a major materials handling company. These simple control systems are extremely cost effective and yet still meet the harshest environmental demands. The machines simply accept a large stack of pallets and dispense 1 or 2 pallets for use.
Features:
Fast Automation consulted to and represented Siemens A&L in a $70m automation project at Sydney Airport to automatically detect explosives in the baggage handling system (BHS) in both T1 and T2. This allowed Sydney Airport to 100% screen all checked baggage for explosives using EDTS (5 beam Explosive Detection Tomography System).
http://www.airport-int.com/categories/xray-security/securitynet-the-shape-of-things-to-come.asp
The project involved supplying and programming of 15 New Siemens S7-400 PLCS, Modifications to several other PLC’s and 2 unlimited Citect SCADA redundant servers with 25 clients.
Primary Tasks included:-
This project required the addition (into a space that was not designed for it) of 5 kilometers of conveyor and 13 EDTS machines.
One of the primary challenges of the project was cutting into the existing baggage handling system and commissioning in small time windows without any disruption to the airports normal operations.
Basically bags that were checked in were diverted and routed through 3D EDTS x-ray machines. The x-ray machines automatically detect suspect bags (termed level 1 failures) then present the suspected bags to a control room of trained inspectors. During the period of inspection the suspect bags go through several levels of decisions, these decisions are also physical areas in the baggage handling system (the 5 th level being a bomb-room).
In addition there are a myriad of other equipment and scenarios that further complicate the solution.
One of the primary challenges of the project was cutting into the existing baggage handling system and commissioning in small time windows without any disruption to the airports normal operations.
Technology used:
Siemens S7-4xx and S7-3xx PLC Systems Coded in Step7 (STL, LAD, FBD and SCL languages)
Siemens Wincc SCADA Version 6 (utilized for PD monitoring and simulation)
Citect SCADA (V6.2) (BHS Primary SCADA system)
Accusort Barcode Scanner Arrays.
Siemens Ecofast High Feature Motor Controllers (On Profibus DP)
Remote I/O units ET200eco, ET200L, ET200s and ET00M variants.
ASi (addition to existing systems)
Danfoss VSD’s
Datalogic Dragon Barcode hand scanners interfaced over Profibus DP
Multiple Serial and Ethernet Communications Interfacing to peripheral devices.
Image of the recorded throughput in one area using Fast Automation’s software. This image highlights that one xray machine’s output was blocking then clearing.:
Image of the recorded throughput in one area using Fast Automation’s software. This image highlights that one xray machine’s output was blocking then clearing.:
Image of generic simultation test rig designed and put together by Fast Automation:
Screen Shot of the actual Traceability matrix used to ensure compliance to requirements policed by Fast Automation:
Image of automatically generated and emailed reports created by Fast Automations software:
BHS actual scada screens, using Citect’s SCADA application:
Issues management using Xylogy project governance system.
Typical Code Change Request Form sample:
Example of PLC Hardware configuration using Step-7:
Brochure image of some of the remote Siemens Hardware used:
An Industry leader in the water mains inspection field contracted Fast Automation to automate a world first inspection system. The system utilises a number of winches to insert a sterile inspection head (on the end of a purpose made Kevlar cable) into live water mains and then examines up to 1.5km of pipeline.
The project involved not only the automation of the mechanical system, but the recording and reporting of the valuable data. The system utilises Wonderware Intouch SCADA and Allen Bradley Rockwell Micrologix PLC’s along with a tablet HMI and two 17″ touchscreens. (click here to view these products) The SCADA application really showcased the capabilities of Wonderware Intouch with some useful animation.
Fast Automation have been undertaking development on the Kinect Camera system from Microsoft to take the system from the Lounge Room to the Factory Floor. Despite it’s origins in gaming, the Kinect camera is a powerful tool for use in Industrial environments, competing with systems at a fraction of the price. The Kinect system incorporates Depth sensing at 512 by 424 pixels, a 1080p colour camera and active infrared capabilities at 30Hz. With a powerful Developers Kit available, the Kinect will become a serious contender in developing bespoke vision and measuring systems.
Fast Automation have been developing bespoke solutions and welcome any opportunities to help with your needs please contact Matthew Lane on 0420 998 553.
Due to Fast Automations reputation for simulating and implementing Critical systems (Solution Preperation, Gas Filling etc), Fast Automation has been requested to design the control system on a Telescope for remote operation in Antarctica. The control requirements are highly sophisticated, but also had to withstand the extreme environmental constraints as well as operate without human intervention.
Antarctica is one of the most inhospitable places on earth, being dark and down to -85 Deg C, for up to 9 months of the year. The controls design therefore, had to cater for multiple levels of redundancy.
The design is in progress, and subject to change, with anticipated installation in 2011. The details of the design are not for public exhibition, but some documentation images are shown below:-
Another Gas Filling System project is deployed to Darwin. It is the latest in a series of new gas filling systems developed for a global gas giant. The systems utilise Siemens PLC’s and Wonderware SCADA together with ET200s IO and Burkert Valve Blocks.
“The use of coding removes human error in fill profile/recipe selection, and the beautiful but cost effective 24″ HD touchscreens ensure the best of operator interfacing” advised Ekawin Sounthornchote Fast Automation’s gas filling systems Lead Engineer.
The fourth of the latest generation of mixed gas filling systems has been deployed to the west coast of Australia. These systems feature a beautiful 24″ HD touchscreen which facilitates the efficient operation of these extensive control systems. These systems capitalise on an earlier development project which created a generic system that is easily tailored to each sites requirements through selection/configuration pages on the SCADA.
Fast Automation has deployed another gas filling system to western Australia. This is the nineteenth system of its kind in Australia and all went well. The systems utilise Wonderware Intouch SCADA and Omron PLC’s. The newer systems utilise plchardware.com.au 17″ Touchscreens and Din Rail PC’s. Fast Automation looks forward to more of the same.