Challenge:

The client was looking for a way to increase their product’s quality and reduce waste by analyzing their materials at the beginning of their manufacturing process. Using a Siemen’s ET 200SP PLC they developed a machine that could measure the thickness and density of their products, but they couldn’t read, store and analyze their data quickly enough due to the software limitations. The client asked Vertech to develop a software package that could transfer data from 5 linear encoders at high-speeds, perform analytics & calculations with that data, and store all of their data on their server for historical trends and future analysis.

 

Solution:

We developed a software solution using Siemens’ WinCC Open Architecture. WinCC Open Architecture gave us the flexibility and power to transfer data at high-speeds due to the event based actions, complete analytics and calculations for the product’s test, and store all of the data on to their servers. Another great feature of WinCC Open Architecture is that the software has object-oriented features for the data-points. This allows us to scale our software for multiple machines as the client expands their facility.

 

Benefits Received by Client:

Previously the client was using 9 points of data to determine the thickness and linearity of their product. Although this information was helpful, it was not 100% effective in detecting failures. With the new system they are able to read up to 5500 points of data per test, perform calculations faster, and store all of their data for future analytics. Overall the client reduced manufacturing cost, increased product quality, and invested in a system that can be easily expanded in the future.

Project Stats

.0001%

Measurement Accuracy

100ms

Measurement Rates Per Encoder

5500

Up to 5500 Data Points Measured Per Test

“The expertise and support that Vertech provided during the development of our Super Mic SCADA project has been exceptional. They’re accessible, easy to work with - it’s a pleasure working with the Vertech team. We look forward to a continued partnership. ”

— Steven Garlick, Sr. Mechanical Engineer

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