Client Challenge
A battery manufacturer was facing significant challenges with its existing control system, which comprised seven industrial computers running proprietary software. This system was difficult to modify and support, posing obstacles to product flow control, part tracking, data collection, and quality checks.
Our client also needed to reconfigure its equipment to accommodate a new product, requiring numerous modifications to the control system. Our team took a cost-effective approach that retained as much of the existing infrastructure as possible while integrating new components, including laser welding and ultrasonic welding equipment.
Our Solution
Our team designed and implemented an upgraded control system to meet the client’s requirements while minimizing costs. Key steps in the project included:
- Scope Development and Planning:
- We documented the existing Sequence of Operations (SOO) and collaborated with the client to redefine the SOO for each station.
- System Reconfiguration and Upgrades:
- The Rexroth IndraDrives were reconfigured to communicate using Ethernet/IP.
- New Cognex camera systems were integrated for vision-based inspections, as well as a new laser, and ultrasonic welding equipment.
- We designed and installed a new 3-axis motion system for the Laser Weld Station.
- Control System Development:
- We developed new ControlLogix PLC code and FactoryTalk View SE Server applications to replace the proprietary industrial PC systems.
- We transitioned communications from Profibus to Ethernet/IP for improved reliability and scalability.
- Pre-FAT and FAT Testing:
- A test environment was established at DSI’s office, including a PLC, SCADA server, thin client, and all critical devices.
- Our team conducted rigorous pre-FAT testing and hosted a customer-witnessed FAT to ensure system readiness.
- Installation and Commissioning:
- We replaced existing Phoenix I/O communications adapters and cables.
- Sensors and devices were added based on modifications to the assembly line.
- We installed a new PLC rack in the main panel, upgraded Festo valve bank communications adapters, and provided additional station wiring.
- We installed and configured the 3-axis motion system at the Laser Weld Station.
- After installation, we completed power-up, commissioning, and startup services.
The Results
Our team delivered a modernized control system that enabled the client to produce their new product efficiently and reliably:
- Enhanced Control and Flexibility: The updated system supported product flow control, part tracking, and quality checks, with features comparable to the proprietary system but easier to maintain.
- Seamless Integration: New equipment, including Cognex cameras and welding systems, was integrated smoothly into the assembly line.
- Improved Communication: The transition to Ethernet/IP from legacy protocols like Profibus and SERCOS increased communication reliability and scalability.
- Cost-Effective Upgrade: By retaining and reconfiguring existing components where possible, we were able to minimize project costs while delivering a robust solution.
- Validated Performance: Pre-FAT and FAT testing ensured system readiness before deployment, reducing downtime during commissioning.
This project demonstrated our ability to modernize complex manufacturing systems, delivering tailored solutions that balance cost-efficiency with advanced functionality.
