The document summarizes a project to upgrade an existing cut to length line from an electromechanical control system to a PLC and SCADA system. A SCADA interface was developed to empower operators to easily reset tripped overloads from a visual interface. Ladder logic was programmed from the original drawings and the control panel was constructed and tested. The SCADA provided control screens to enter recipes, a numeric interface to enter quantities and sizes, and diagnostic pages that mimicked the actual control panels to reduce downtime.

1. Trident Cut to length Project
Integrated by Paul Bester
A project for DCB Automation

2. Cut to length line upgrade.
• The scope of this project was to upgrade an existing
Electromechanical control system on a cut to Length line, to a PLC and
SCADA system.
• The SCADA should be so user friendly, that it would empower the
operator to reset tripped overloads in the Control Panel with a visual
animated SCADA interface.

3. Steel cut to length line.

4. Coil Car and Un-coiler, Leveler With the
control station in the foreground.

5. Control Station and Leveler.

6. Plc Interface.
• The plc interface were programmed and tested in house at the Factory.
• Ladder logic diagrams were created from the original electrical drawing of the electromechanical drawings.
• The control panel were constructed and tested with the SCADA interface in the workshop.
• The SCADA and Ladder programming were all done by Me.
• Scope of the SCADA requirements:
• Control screens were created where the recipe with the required quantity’s, Sizes and batch numbers could
be entered on a touchscreen.
• A number pad numeric interface were created that allowed the user to enter the required recipe.
• Diagnostic pages with virtual panels were created that mimicked the actual as build panels.
• Tripped overloads or VSD’s would flash red on the diagnostic page with a cross reference to the specific
panel.
• This reduced down time significantly in the new refurbished line.