Automation And Controls5 10

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Automation And Controls5 10

  1. 1. Automation and Controls Tamper Resistant Little Tikes Key Lock ABC Shielded Harley Davidson Top Sealer Auto Positioner Auto-Assembly Glovebox Radioactive Robotic Crating Applicator Isotope Closing Station System 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  2. 2. Specific Automation Capabilities Automation Hardware Platforms HMI Systems Labview, Wonderware and • PLC – Rockwell Automation, GE Intellution Fanuc and Modico • PC Based - National Instruments • DCS Platforms – Info-90 and Emerson Delta-V • Vision Systems – National Instruments and Cognex • Robotic Systems • Communication Protocols – CAN Bus, Mod Bus, Ethernet/IP, RS -232, RS-485 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  3. 3. Process and Discrete Automation Capabilities • Automated Weld Systems • Punch and Drill Equipment • Temperature, Flow, and PH Control Systems • Vibration, Optical, etc. • Data Acquisition Systems • Alternative Energy Systems • Packaging Systems • Quality and End of Line Tester Systems 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  4. 4. Honeywell GTA Welder Control System Upgrade • Honeywell Federal Manufacturing and Technologies LLC utilize high-precision welders for the U.S. Department of Energy • Honeywell wanted an upgrade to be developed with Commercial Off-The-Shelf (COTS) hardware and open- source software so it could be easily supported and expanded in the future without having to be completely redesigned • Innoventor’s solution provides a Host PC (Windows XP) with a touch-panel computer (Windows CE) for user interfaces • All of the software was written using LabVIEW 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  5. 5. Honeywell Federal Manufacturing and Technologies EB Welder Programming and Hardware Updates • The Customer asked Innoventor to create a new control system for their high precision electron beam welder • The new system needed to meet very tight timing requirements and maintain/improve the system safety features • The Team used National Instruments hardware and LabVIEW software to create the new control system “The project… exceeded our expectations with respect to performance and ease of • Innoventor also updated the user interface to use…(Innoventor) came up with innovative provide process improvements and reduce solutions to numerous challenges throughout…” operator input errors Letter of Commendation from Honeywell’s Principle Weld Engineer 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  6. 6. Bausch and Lomb Surgical System Testing and Validation Software • Bausch & Lomb, a major manufacturer of eye health and ophthalmic surgical products sought Innoventor’s expertise in developing test software for a new anterior eye surgery system • The system includes six to 12 modules (including a controller PC), each with different functionality, all communicating with one another via a CAN communications network • Innoventor utilized the great synergy of NI’s LabVIEW and TestStand packages, developed a robust software architecture with rich features bringing great value by delivering a suite of inter- connected software packages that served different needs but re-used much of the same code 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  7. 7. Mold Drawer Automation Major Heavy-equipment Manufacturer • Innoventor developed an automated system for moving mold sections into and out of molding presses • Fourteen presses run a total of 100 different molds; each mold containing several different sections, or drawers • The system uses hydraulic cylinders with electromagnetic end affecters to allow the operator to move the drawers into the press, as well as, remove the drawers at the push of a button • The hydraulic cylinders are vertically adjustable and designed to accommodate more than 100 different molds • The system uses electromagnets to attach all of the different drawer types, minimizing the modifications made to the mold drawers 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  8. 8. BD Diagnostics - Accu-Glass Automated Parts Handling System • Innoventor developed an automated handling system for a cleaning process using hydrofluoric acid, a substance that is very hazardous to human health • The previous cleaning process required the manual placement of material into a bath of hydrofluoric acid and a health risk • The new system: - Consists of a 2-axis configuration that moves the basket in and out of the hydrofluoric baths and rinse tank -Required the chemical compatibility of the materials used in the handling system -Used PVDF(Kynarr) plastic for the gripper due to its excellent chemical resistance to hydrofluoric acid as well as its dimensional stability and mechanical strength 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  9. 9. Comtrak Technologies, LLC Redesign of Digital Video Recorder Update VCU Enclosures • Innoventor developed a solution for the complete redesign of an existing Digital Video Recorder and an upgrade series of enclosures and packaging for a new line of digital video recorders for use in the surveillance and security industry • The box design had to maintain certain existing components and commonality while allowing for the use of “Hot Swap” hard drives that could be used in 2 different style of boxes (A 4 channel unit and a 16 channel unit) • The outer enclosures and internal structures were designed and packaged to securely house all components and allow adequate access for service while minimizing production costs • Numerous tang-in-slot type self location/fixturing features were incorporated to allow for reduced down time and simplified assembly and maintenance 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  10. 10. Vision Hardware Equipment Interface Dell laptop for file storage and Trigger input parameter adjust ET Hub Iomega camera RS-232 interface Robot Controller Robot shown as example only. LCD Monitor displaying real IR Camera National Instruments time image and CVS-145x results This document is the property of Innoventor, Inc. It may not be reproduced without Innoventor, Inc. written permission or used for other than Innoventor, Inc. authorized purposes. 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  11. 11. Chemical High Speed Processing Equipment • Bag Fill Line design met a critical and highly defined pharmaceutical requirement for sterile processing of a blood based product • A PLC controls two of the Sigma Chemical Lines – Clean in Place and Product Mode Sigma Chemical Bag Sigma Chemical Bag Serum Fill Line Serum Fill Line 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  12. 12. Harley-Davidson Robot • The Robotic Crating System is an automated recyclable crating system that allows for repeated use of motorcycle packaging • Innoventor project managed the build of this automated system on site Harley-Davidson Robotic Crating System 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  13. 13. First Tier Automotive Supplier Key and Lock Line • Innoventor is the first outside source to build a machine for this first tier automotive industry supplier • Reverse engineered this system from hundreds of photos and measurements of an existing line in the plant • The line assembles and checks complete key/lock sets • Automated line has 12 stations, 6 with Allen Bradley PLCs and a final 100% check GE Fanuc Robot 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  14. 14. ABC Labs Automated Processing Equipment • The automation enclosed in the Glovebox drastically reduces manual operations used in processing a specific highly sensitive pharmaceutical product • PLC controls used for the automated glovebox are concept software and Modicon ABC Labs Automated Glovebox PLCs 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  15. 15. Republic of Tea High Speed Tea Bagger Equipment • Innoventor designed and built this automated process to sort and pack round tea bags into canisters • Allen Bradley PLCs • 2000 bags per minute(500 per lane) 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  16. 16. Little Tikes Automated Welding Equipment Little Tikes Automated Positioning and Robotic Welding Systems Automated Commercial Play System 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  17. 17. Plant Automation High Production CNC Controlled Machines A PLC controls this Motor End shield drill, ream and bearing press for a fractional horsepower electric motor manufacturer 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  18. 18. Republic of Tea Top Seal Applicator • Optimized the software & pneumatics to increase the response time • 3 cameras used to first find a barcode and then second to give the location of the edge of the barcode • The seal applicator was able to calculate the amount of rotation to orient the can for top seal application 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  19. 19. Husky Corporation Laser Marking System • Laser technology designed to burn serial number and product information onto gas nozzle connections • Designed for easy operator interface with a high level of dependability and safety • Significantly increased the customers production over the manual hand stamping previously employed 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  20. 20. B-D Vision Systems Vision Inspection Systems • Allen Bradley PanelView touch screen operator interface • Precision Haas rotary index table, accurate placement to ± 15 arc-sec • Allen Bradley SLC 5/03 controller Becton Dickinson Accu-Glass Rotary Index Vision Inspection Machine 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  21. 21. Nascote Automated Production Equipment • Automated equipment that applies information labels to the curved grill surface of Ford SUVs • Allen Bradley PLC Controls Nascote Industries Label Applicator 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  22. 22. Overview of LabVIEW Projects Innoventor, Inc. Glucose Meter Tamper Resistant Probe Hardware Navy FLIR Circuit Breaker Top Sealer Applicator Simulator Optical Alignment Tool Slake Tester Testing 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  23. 23. A Quick Word About Innoventor Got problems? We have solutions! • Full service integrator specializing in NI tools and hardware • NI certified developers and architect • Certified Alliance Member since 1994 • Innoventor engineering team 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  24. 24. NI Expertise • LabVIEW – Many programming projects and turn-key systems successfully delivered – Specialty areas including Real Time, Vision, Motion, Control, Simulation, Data Presentation, Connectivity, etc. • NI hardware platforms: PC, PXI, FieldPoint, cFieldPoint, SCXI, Compact Vision, etc. 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  25. 25. Top Sealer Application • Apply a top seal with wings to a can – Top seal safety assurance – Can 2” diameter by 6” tall • In feeding and out feeding of cans • Sort cans with different labels, up to 5 types, after top seal application • Many different label types that represent can contents – No restriction on graphics – Only the bar code is present on every label 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  26. 26. Machine Overview Operator screen Sorting tables In-feed conveyor Panel with PAC Power condition and motor drives 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  27. 27. Hardware Diagram 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  28. 28. Slake Tester • Production and quality control test system – LabVIEW executable – USB data acquisition device (USB-9211) • Automate procedure of testing reactivity per ANSI standard – Elimination of errors in data recording – Logging of results – Minimize operator training 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  29. 29. Slake Tester Interface 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  30. 30. Circuit Breaker Production Life Testing • PXI based and distributed • High speed synchronous sampling on multiple channels • Matrix switching used to multiplex inputs from test cells • Synchronized triggering form Ia master controller Ib Ic • Separate PXI system used to Va Vb Vc simulate master controller and 3Phase Breaker test data Load Bank 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  31. 31. Data ACQ Hardware Overview • Analog input (NI PXI-6115 Qty 3) – 12 bit, 10MS/s each channel – 4 channel, simultaneously sampling – 500 kHz/50 kHz 3 pole Chebyshev filter software selectable on channel basis • Matrix switch (NI PXI-2503 Qty 2) – Used to route individual breaker voltage and current sensors to analog sampling inputs – 4 x 6, 2 wire (provides signal pairs for noise immunity) • Digital I/O (NI PXI-6527) – 24 inputs – 24 outputs – 0 to 30 volt 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  32. 32. Navy FLIR Optical Alignment Tool Improvement • LabVIEW program to monitor real time measurements and log stability tests • Electronic 2-axis autocollimator read using DAQ in PXI chassis • Thermocouples monitoring gradients read using FieldPoint modules Measurements Modeling and Design Test Set Up Test 2 Data 90 70 Alignment (arc-sec) 50 Xpos(arc-sec) 30 Ypos(arc-sec) 10 -10 19 21 23 25 27 29 -30 Temp (deg C) 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  33. 33. Test and Measurement New Product Development • Kinetic hammer with auto feeding nail strip for use on products such as house wrap and roof felt • Accelerometer measurements used to “see inside” and time interactions Accelerometer Horizontal Orientation 100 Response 80 60 40 during 20 accel 0 accel 0.6 0.65 0.7 0.75 0.8 -20 hammer impact -40 -60 -80 -100 time(sec) 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  34. 34. Automation, Inspection, and Test Systems • National Instruments LabVIEW and numerous hardware platforms • Unique vision inspection methods • Systems for process control and Test 2 Data product evaluation 90 70 Alignment (arc-sec) 50 Xpos(arc-sec) 30 Ypos(arc-sec) 10 -10 19 21 23 25 27 29 -30 Temp (deg C) 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  35. 35. High Resolution Optical Inspection • Glass rod (1mm diameter x 10mm length) with small center channel for flow control in medical product • Application created in Vision Builder and LabVIEW to screen for “extra” channels • Clear glass and small features present unique imaging challenges • Illumination source created to make the channels light up in the image • System was tested for gauge read and repeatability and surpassed requirements significantly 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  36. 36. Glucose Meter Probe Hardware Simulator 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  37. 37. Using FieldPoint and LabVIEW Application for Production Unit Verifications 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  38. 38. Test/Certification System for Enteral Feeding Pumps 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  39. 39. Nano-particle R/D Reactor Controller • Very dynamic control and data collection system used for a chemical reactor in development of nano- particles • User can assign up to 48 independent PID thermal control loops without modifying the program • Data I/O can be remapped by user without changing code • Tags are assignable to view groups for quick access to similar parameters • Also includes monitoring and command of motors, mass flow meters, pressure sensors, etc. 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  40. 40. Liquid Chemical Pilot Plant R/D • Control and data collection system for research and development of a liquid chemical production • Wide range of interfacing – Multiple RS-232 – ModBus – 4-20 mA – Discrete I/O – Analog volts • Shutdown control and monitoring implemented from program • System has made many day runs without incident 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  41. 41. Automated Wheel Audit Test Station • Rack mounted PC based system with DAQ and Motion • Application written entirely with LabVIEW development system • Fully automated measurement and analysis of wheels – Four attributes of run out – Selectable speed of operation – Synchronized LVDT sampling with angle – Exact repositioning for marking – Plots comparing to 1st harmonic and calculation of 20 harmonic terms • Precise to within 0.001 inches 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  42. 42. Development of Genset for Alternative Power • Application written entirely with LabVIEW development system and includes remote monitoring with DataSocket • Broad range of interface hardware – SCXI (TCs, Pressure, Flow, Power) – SCXI relay for load bank control – DAQ for fast cylinder pressure – RS-232 for emissions gas analyzer – CAN for generator control/monitor and for engine control/monitor – RS-485 for power meter communications 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  43. 43. Portable Oxygen Unit Production Test System Print • Production test system is part er RS- of the final test of a medical Comput 232 Unit Under Test Flow product which dispenses er Pressu re meter oxygen on demand to conserve DAQ card SCB- 68 Flow Breathin the supply Analog signals g simulato • Original testing done using a r manual approach and required 3 people on 2 shifts (6 total) to maintain production rates • Test system reduced manpower to 1 person on 1 shift and still has excess capacity for production rate increases 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044
  44. 44. Innoventor, Inc. A Solutions Engineering House 3600 Rider Trail South St. Louis MO 63045 (USA) P 314.785.0900 F 314.785.0044 www.innoventor.net 3600 Rider Trail South A Top 50 Company phone:314.785.0900 St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044

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