Month: April 2017

Fast-Automation was given a NZ based project to improve detection of non filled gas cylinders. The filling of medical oxygen is done in batches of up to 40 cylinders, sometimes a cylinder is not filled (for example due to a faulty valve). Although this only happens rarely, an unfilled medical oxygen cylinder can be life threatening, therefore detecting them is extremely important. Fast Automation welcomed the challenge and after several trials took the path of using thermal imaging. Fast Automation then developed a bespoke active X and embedded it into Wonderwares intouch SCADA solution, this is interfaced to the Allen Bradley Control Logix PLC based fill system. The system is initially being deployed to several sites in New Zealand. “ Even we are surprised at how effective this solution has been ” remarked David Fonseca – FA systems engineer. In addition to meeting the initial project aim the system has shown the potential to provide other process benefits.

The screen shot shows the contrast of a non filled cylinder:

Fast Automation has been awarded a valuable project to provide pumping control systems to the gas industry. The systems are outdoor high availability systems with ABB, Siemens, Festo and Cermate technology. The systems can have back to base reporting and remote connection for diagnosing faults. The units have fallback modes and feature substantial derating and redundancy in the design. “The selection of hot swappable hi availability hardware also helped our solution win” advised Matthew Lane, a Senior Project Manager at Fast Automation.

Fast Automation was given the opportunity to enter the exciting and innovative laundry rail systems market by a laundry giant.

The systems involved interfacing to various industry standard machines including Milnor, Jensen and Senking. Which have bespoke clocked I/O type communications.

The Rail systems are unique in that the power source is essentially gravity. The product is raised or loaded via a hoist, which releases the bag onto a ceiling mounted rail system. The product is tracked into and out of zones using points and stops, using a mono rail with amazing efficiency (compared to conveyor systems). The systems ultimately drop off/release the laundry to various locations. These drop points could be folding tables, washing machines, dryers etc.

The system seems to be almost exclusive to the laundry industry but, could readily be adapted to other industries.

The Technolgy utilized includes the following:-

• Wonderware Intouch 9.5, using OPCLink I/O server.
• Compact Logix L32 PLC Processors.

Below are some screen prints from the system and photographs.

Fast Automation integrated 5 Sick VMS (Volumetric Sensing Systems) units into Sydney Airport.

Sydney Airport’s baggage handling system experienced at least one baggage item that was over the prescribed limits, baggage caused expensive damaged to a critical high speed sorting conveyor loop. This in turn impacted the airports ability to process bags and thus had a double impact on operations.

Fast Automation integrated into 5 key locations Laser Measurement units, these units simply measured the bags, checked them against SCADA adjustable limits and stopped them from advancing (with associated alarms) if over the limits.

Primary Tasks included:-

1. FDS (Functional Design Specifications) development
2. DDS (Detailed Design Specifications) development
3. Code development.
4. FAT and SAT testing.

Technology used:
Siemens S7-4xx PLC Systems Coded in Step7 (STL)
Citect SCADA (V6.2) (BHS Primary SCADA system)
SICK VMS200 Laser Scanners
ET200s ASCII to Profibus Convertors

Following is a small section from the installation documentation:

A local Robotics company was contracted to implement a staff saving robot, by a large Pharmaceutical Company: AstraZeneca. AstraZeneca also requested that the company use Fast Automation for the control system as we are a preferred supplier.

The project was very straightforward and involved a small S7-300 Siemens PLC, a Touchscreen and Movidrive Servo technology.

Fast Automation’s Roles:

• Requirements Analysis.
• Detail Design (SMDS) and Electrical Drawings.
• ITD development.
• Attend Customer progress Meetings.
• FAT and SAT attendance.

The project was executed on time and within budget.

Key to the success was the demarcation/interfacing of contractors with the use of an IDT (Interface Data Table) Fast Automation introduced this to the relevant parties involved, and thereby maintained control of the project.

Fast Automation is presently finishing the delivery of one Solution Prep suite and installing another two for Astrazeneca in North Ryde. The suites are used to automate the manufacture of solutions for human injection and comprise the following:

• Approx 4000 IO points
• 6 SCADA Stations
• 6 Large PLC Systems
• 12 Remote I/O Stations
• 11.7m wide by 2m High Main Control Panels

The system software is tested via a simulation rig and features the following systems:

• Domain Controller Server
• SQL Server and Historian Server
• Valve/Sequence Matrix Machine
• Actual SCADA Machine
• PLC Programmer Machine
• Simulation Machine
• Main PLC
• Downstream PLC

A Mitsubishi Alpha PLC was punching above its weight division on an automated punnet bagging machine. The prototype machine was failing to complete its trial run.

After a brief consultation Fast Automation swapped the PLC for a Hitachi EH-micro 40 I/O unit with a baby Cermate HMI. Although a simple application to program (it only took an afternoon). It was a complex application to implement on the FBD based Alpha controller.

The machine designer’s faith in PLC’s was restored after seeing how easy the system was to automate with the correct technology. Fast Automation look forward to working with this new company again soon. Fast Automation were recently appointed Australian distributers for Hitachi PLC and Drives.

Fast Automation recently completed a process control system for the production of slow release agents/additives. The first pilot plant was recently completed here in NSW. It utilizes a multi staged batching system with a control system custom designed by Fast Automation. The automation is based on Wonderware Intouch SCADA, Siemens S7 PLC, Siemens/Burkert ET200s IO and valve blocks and SEW drives. The project involved a Hazardous zone of intrinsically safe IO. The primary Human Interface is through a 19″ Norco Touchscreen. The client was particularly happy with the infinite recipe system based in excel and the ability to fully simulation test the control system prior to operation.

Fast Automation was contracted to consult and commission on a project that was over running and failing to work. After a brief overview of the system a new PLC and control cabinet was ordered; to rectify performance and topology deficiencies associated with the existing micrologix based design.

System overview

The system comprised MPI xray machines, a number of barcode scanners and Imaje Ink Printers. The concept was relatively simple, when the xray determined a box contained a foreign object (via its internal algorithm, then a message with the result was forwarded to the PLC. When the box reached the barcode scanners the code was used to look up if the box had passed. If the box did not have a pass recorded in the database then the ink guns fired to prevent downstream systems from packing it.

Technology Utilised:

• Compact Logix
• Devicenet to serial bridges (1734-232) point I/O
• RSLogix5000
• Sick Barcode Scanners
• Serial tools including Docklight (for testing)

Fast Automation was contacted to replace a non functioning antiquated Hitachi H Series PLC and PWS Hitech Touchscreen. The project involved removing the existing H200 PLC and PWS2200 Touchscreen and replacing it with an EH-150 PLC and ESA Touchscreen urgently.

The project was difficult due to the age and criticality of the system. The Data centre is the lifeline to major banking systems and local ISP providers.

Also the existing peripheral system did not work fully and a number of Modbus devices required replacement. Fortunately the system was subjected to a real outage and required to work only one week after the upgrade.