HMI & SCADA

PCT also specializes in providing well conceived human machine interface (HMI) systems. Our work is driven by input from your operators. We are experienced in developing applications for machine operation and troubleshooting, recipe management (to reduce setup time and variation), production data tracking, and interfacing to enterprise software.

Machine Setup

To assist operators in reducing changeover time between products, PCT was asked by a manufacturer of high value plastic film to create a machine setup system. The machine setup required a large number of variables to be recalled using a recipe format. Using industry standard software tools, PCT developed a flexible recipe system that met all of the customer requirements.

Product identification numbers are used to select a recipe of interest using a drop down selection screen. Operators then recall the recipe operating parameters using a single touch button. A combination of scripts and stored procedure calls query the database and present the suggested recipe parameters to the operator. The operator has the option to use the parameters as recalled or may modify these variables prior to running the system. Modification of existing and creation of new recipes is handled through a password protected screen.

An automatic report is generated during operation to conform to ISO requirements to verify operating parameters during runtime. The PCT system compares the actual operating parameters to the desired values and highlights any “out of spec” numbers in the report. This reduces the time required to compare 80 parameters for conformance.

The automated machine setup system utilizes standard scripting tools found in all the major SCADA software packages. The SQL database queries were handled using rules and stored procedure calls. A well architected database schema allowed PCT to make significant changes to the system during deployment without delays or cost increases. By utilizing these industry standard tools, the entire machine setup system can be transported to any major SCADA package.

Industrial Automation Industrial Automation

Production Tracking

Integration of your machine controls can improve your productivity and lessen your downtime; but plant and company-wide access to data from your automation control systems is an increasingly important concern for most companies. Imagine what company-wide integration of process data can do for you…

PCT has experience in developing production tracking systems. As an example, we produced a system for John Deere's Davenport Works to track the parts on the main conveyor of their paint line. We designed a multiple tier system, including plant floor PLC controls and production tracking via a series of databases. PCT was then selected to design, develop and commission the conveyor control system for the manufacturer using a PC based client/server configuration. Message queue architecture was implemented to transport data to the inventory database and the payroll host. The completed system provided "better control of (our) production schedules" and enabled Deere "to give our dealers exact delivery dates for orders".

The PCT Innovation Group can employ a powerful combination of I.T. tools and plant floor automation controls experience. The result is a tightly integrated system of controls and data.

Industrial Automation Industrial Automation

Upgrades & Refurbishment

Often times a completely new piece of equipment is not required to address additional process requirements. In these situations the PCT team excels at identifying and delivering solutions that enhance the performance of legacy systems. We have the practical experience to know how best to design new components that effectively integrate with an existing process line. The revisions may include modifications to mechanical devices, a new control system, or modern operator stations.

 Upgrade Project Results:

  • Increased production rates
  • Improved operator safety
  • Additional functionality
  • Product quality improvements
  • More maintainable equipment

Refurbishment work can either be performed at PCT's facility or on-site. The scope of PCT's involvement may range from providing one part to planning and executing a complete turnkey project. We have the flexibility to respond to your specific needs.



 

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