Industrial Servo-Control Development Specialist Needed
Budget: ₹100,000 – ₹150,000 INR
Delta PLC, Servo Motion, HMI and SCADA Programmer Required
Project Overview
We are developing two industrial servo-controlled products:
1. Servo Nutrunner
2. Servo Pressing Spindle
We require an experienced PLC, servo-motion, HMI and SCADA programmer to develop the control software, operator interface, graphical process monitoring, data logging, reporting and machine diagnostics.
This is not only an HMI-development assignment. The programmer must have practical experience in servo motion control, torque-angle monitoring, force-displacement monitoring, PLC programming, industrial communication, database integration and machine commissioning.
Proposed Hardware
Servo Nutrunner
* Controller: Delta PLC
* Servo drive and motor: Delta ASDA-B3
* Torque feedback: Servo-drive torque feedback and/or external torque transducer
* Angle feedback: Servo motor encoder
* HMI/GUI: Delta HMI, VB.NET, C#, Lua or suitable industrial SCADA
* Communication: EtherCAT, CANopen, Modbus TCP/RTU or another suitable protocol
Servo Press
* Controller: Delta PLC
* Servo drive and motor: Fuji Electric ALPHA7
* Force measurement: Load cell with amplifier
* Displacement measurement: Servo encoder, rotary encoder or linear encoder
* HMI/GUI: Industrial HMI or Windows-based application
* Database: SQL Server Express or another approved database
Scope 1: Servo Nutrunner
The operator shall be able to create and save tightening recipes containing:
* Target torque
* Target angle/theta
* Minimum and maximum torque
* Minimum and maximum angle
* Rundown speed
* Final tightening speed
* Acceleration and deceleration
* Snug/seating torque
* Torque hold time
* Cycle timeout
* Reverse speed and angle
* Part number, recipe and batch quantity
The tightening sequence may include:
1. High-speed rundown
2. Snug-point detection
3. Low-speed tightening
4. Torque-controlled tightening
5. Torque-plus-angle tightening
6. Hold or verification
7. Controlled stop and reverse
8. OK/NOK evaluation
The system must record:
* Actual torque and angle
* Peak and final torque
* Final angle
* Tightening time and cycle time
* Torque-versus-angle curve
* Torque-versus-time curve
* Pass/fail result
* Failure reason
Typical rejection conditions:
* Torque above or below limits
* Angle above or below limits
* Target torque not reached
* Early torque rise or cross-threading
* Excessive rotation or stripped thread
* Cycle timeout
* Servo or communication alarm
Scope 2: Servo Pressing Spindle
The operator shall be able to create and save pressing recipes containing:
* Target force
* Minimum and maximum force
* Target displacement
* Minimum and maximum displacement
* Approach, pressing and return speeds
* Acceleration and deceleration
* Contact-detection force
* Force or position hold time
* Upper force-displacement limit
* Lower force-displacement limit
* Intermediate checking windows
* Part number, recipe and batch quantity
The pressing sequence may include:
1. Home-position verification
2. Component-present verification
3. High-speed approach
4. Low-speed component search
5. Contact detection
6. Controlled pressing
7. Force/displacement monitoring
8. Hold stage
9. Return to home
10. OK/NOK evaluation
Required operating modes may include:
* Press-to-position
* Press-to-force
* Force-limited position control
* Position with force monitoring
* Force with displacement monitoring
* Multi-stage pressing
The system must display and store:
* Force-versus-displacement curve
* Force-versus-time curve
* Displacement-versus-time curve
* Maximum and final force
* Maximum and final displacement
* Contact position
* Cycle time
* Pass/fail result
* Failure reason
The actual pressing curve must be compared with configurable upper and lower envelopes. The system should also support multiple checking windows at selected force or displacement ranges.
HMI and GUI Requirements
The HMI/GUI should include:
* User login
* Automatic cycle
* Manual/setup mode
* Recipe creation and selection
* Live torque-angle graph
* Live force-displacement graph
* Previous-cycle graph
* Large OK/NOK indication
* Batch and production counters
* Alarm screen and alarm history
* Servo diagnostics
* PLC I/O diagnostics
* Calibration screen
* Maintenance screen
* User management
* Data search and report screen
SCADA and Traceability
Every cycle must be stored with:
* Date and time
* Shift
* Operator name/ID
* Machine number
* Product and part number
* Serial number
* Batch number
* Recipe name and revision
* Target values
* Actual measured values
* OK/NOK status
* Failure reason
* Cycle time
* Torque-angle or force-displacement curve
Users must be able to search records by date, shift, operator, part number, serial number, batch, recipe and OK/NOK status.
Reports required:
* Individual cycle report
* Batch report
* Shift and daily production report
* Operator-wise report
* Part-wise report
* OK/NOK and rejection summary
* Alarm-history report
Reports should be printable and exportable to PDF, Excel or CSV. Database backup and restoration must be provided.
User Access and Security
Access levels should include:
* Operator
* Setter
* Supervisor
* Maintenance
* Quality
* Administrator
Recipe editing, calibration, limit changes and user creation must be password protected. The system should maintain an audit trail of logins, recipe changes, calibration changes, alarm acknowledgements and manual overrides.
Calibration and Diagnostics
Calibration facilities are required for:
* Torque
* Load cell
* Angle
* Displacement
* Zero and span
* Calibration factor
* Calibration date and due-date warning
Alarms should cover:
* Servo not ready or servo fault
* Encoder fault
* Torque/load-cell fault
* Overtravel
* Home-position fault
* Emergency stop
* Safety-door open
* Excess torque or force
* Cycle timeout
* PLC/servo/database communication failure
* Printer failure
* Workpiece not present
Deliverables
The programmer must provide:
1. Complete editable Delta PLC source program
2. Delta ASDA-B3 parameter file
3. Fuji ALPHA7 parameter file
4. Complete editable HMI/GUI/SCADA source code
5. Database structure and scripts
6. PLC I/O list and communication register map
7. Alarm list
8. Recipe parameter list
9. Functional description and sequence of operation
10. Installation and backup instructions
11. Calibration procedure
12. Operator and maintenance manuals
13. FAT procedure and test report
14. Training and commissioning support
15. Complete source-code and password handover
Compiled-only or password-locked software will not be accepted. Intellectual-property rights for the project software must be transferred to us after payment.
Required Skills
Applicants should have experience in:
* Delta PLC programming
* Delta ASDA-B3 servo programming and tuning
* Fuji ALPHA7 servo programming and tuning
* Position, speed and torque control
* Servo homing and motion sequences
* Torque-angle nutrunner systems
* Force-displacement servo presses
* Load-cell and encoder integration
* EtherCAT, CANopen and Modbus
* Delta HMI, WinCC, VB.NET, C# or Lua
* SQL database development
* Real-time graph plotting
* PDF/Excel/CSV reporting
* Industrial alarms and safety interlocks
* Machine commissioning
Experience in automotive assembly, electric nutrunners, press-fit monitoring, process-signature analysis and production traceability will be preferred.
Questions Applicants Must Answer
1. Have you developed a torque-angle nutrunner?
2. Have you developed a force-displacement servo press?
3. How will you capture high-speed curve data?
4. How will the press curve be compared with upper and lower limits?
5. Which communication protocol do you recommend?
6. Which GUI platform do you recommend and why?
7. How will cycle data and graphs be stored?
8. Can you provide remote and on-site support in Bengaluru?
9. Will you provide complete editable source code?
10. What is your milestone-wise price and schedule?
Expected duration: approximately 15 days.
Project Overview
We are developing two industrial servo-controlled products:
1. Servo Nutrunner
2. Servo Pressing Spindle
We require an experienced PLC, servo-motion, HMI and SCADA programmer to develop the control software, operator interface, graphical process monitoring, data logging, reporting and machine diagnostics.
This is not only an HMI-development assignment. The programmer must have practical experience in servo motion control, torque-angle monitoring, force-displacement monitoring, PLC programming, industrial communication, database integration and machine commissioning.
Proposed Hardware
Servo Nutrunner
* Controller: Delta PLC
* Servo drive and motor: Delta ASDA-B3
* Torque feedback: Servo-drive torque feedback and/or external torque transducer
* Angle feedback: Servo motor encoder
* HMI/GUI: Delta HMI, VB.NET, C#, Lua or suitable industrial SCADA
* Communication: EtherCAT, CANopen, Modbus TCP/RTU or another suitable protocol
Servo Press
* Controller: Delta PLC
* Servo drive and motor: Fuji Electric ALPHA7
* Force measurement: Load cell with amplifier
* Displacement measurement: Servo encoder, rotary encoder or linear encoder
* HMI/GUI: Industrial HMI or Windows-based application
* Database: SQL Server Express or another approved database
Scope 1: Servo Nutrunner
The operator shall be able to create and save tightening recipes containing:
* Target torque
* Target angle/theta
* Minimum and maximum torque
* Minimum and maximum angle
* Rundown speed
* Final tightening speed
* Acceleration and deceleration
* Snug/seating torque
* Torque hold time
* Cycle timeout
* Reverse speed and angle
* Part number, recipe and batch quantity
The tightening sequence may include:
1. High-speed rundown
2. Snug-point detection
3. Low-speed tightening
4. Torque-controlled tightening
5. Torque-plus-angle tightening
6. Hold or verification
7. Controlled stop and reverse
8. OK/NOK evaluation
The system must record:
* Actual torque and angle
* Peak and final torque
* Final angle
* Tightening time and cycle time
* Torque-versus-angle curve
* Torque-versus-time curve
* Pass/fail result
* Failure reason
Typical rejection conditions:
* Torque above or below limits
* Angle above or below limits
* Target torque not reached
* Early torque rise or cross-threading
* Excessive rotation or stripped thread
* Cycle timeout
* Servo or communication alarm
Scope 2: Servo Pressing Spindle
The operator shall be able to create and save pressing recipes containing:
* Target force
* Minimum and maximum force
* Target displacement
* Minimum and maximum displacement
* Approach, pressing and return speeds
* Acceleration and deceleration
* Contact-detection force
* Force or position hold time
* Upper force-displacement limit
* Lower force-displacement limit
* Intermediate checking windows
* Part number, recipe and batch quantity
The pressing sequence may include:
1. Home-position verification
2. Component-present verification
3. High-speed approach
4. Low-speed component search
5. Contact detection
6. Controlled pressing
7. Force/displacement monitoring
8. Hold stage
9. Return to home
10. OK/NOK evaluation
Required operating modes may include:
* Press-to-position
* Press-to-force
* Force-limited position control
* Position with force monitoring
* Force with displacement monitoring
* Multi-stage pressing
The system must display and store:
* Force-versus-displacement curve
* Force-versus-time curve
* Displacement-versus-time curve
* Maximum and final force
* Maximum and final displacement
* Contact position
* Cycle time
* Pass/fail result
* Failure reason
The actual pressing curve must be compared with configurable upper and lower envelopes. The system should also support multiple checking windows at selected force or displacement ranges.
HMI and GUI Requirements
The HMI/GUI should include:
* User login
* Automatic cycle
* Manual/setup mode
* Recipe creation and selection
* Live torque-angle graph
* Live force-displacement graph
* Previous-cycle graph
* Large OK/NOK indication
* Batch and production counters
* Alarm screen and alarm history
* Servo diagnostics
* PLC I/O diagnostics
* Calibration screen
* Maintenance screen
* User management
* Data search and report screen
SCADA and Traceability
Every cycle must be stored with:
* Date and time
* Shift
* Operator name/ID
* Machine number
* Product and part number
* Serial number
* Batch number
* Recipe name and revision
* Target values
* Actual measured values
* OK/NOK status
* Failure reason
* Cycle time
* Torque-angle or force-displacement curve
Users must be able to search records by date, shift, operator, part number, serial number, batch, recipe and OK/NOK status.
Reports required:
* Individual cycle report
* Batch report
* Shift and daily production report
* Operator-wise report
* Part-wise report
* OK/NOK and rejection summary
* Alarm-history report
Reports should be printable and exportable to PDF, Excel or CSV. Database backup and restoration must be provided.
User Access and Security
Access levels should include:
* Operator
* Setter
* Supervisor
* Maintenance
* Quality
* Administrator
Recipe editing, calibration, limit changes and user creation must be password protected. The system should maintain an audit trail of logins, recipe changes, calibration changes, alarm acknowledgements and manual overrides.
Calibration and Diagnostics
Calibration facilities are required for:
* Torque
* Load cell
* Angle
* Displacement
* Zero and span
* Calibration factor
* Calibration date and due-date warning
Alarms should cover:
* Servo not ready or servo fault
* Encoder fault
* Torque/load-cell fault
* Overtravel
* Home-position fault
* Emergency stop
* Safety-door open
* Excess torque or force
* Cycle timeout
* PLC/servo/database communication failure
* Printer failure
* Workpiece not present
Deliverables
The programmer must provide:
1. Complete editable Delta PLC source program
2. Delta ASDA-B3 parameter file
3. Fuji ALPHA7 parameter file
4. Complete editable HMI/GUI/SCADA source code
5. Database structure and scripts
6. PLC I/O list and communication register map
7. Alarm list
8. Recipe parameter list
9. Functional description and sequence of operation
10. Installation and backup instructions
11. Calibration procedure
12. Operator and maintenance manuals
13. FAT procedure and test report
14. Training and commissioning support
15. Complete source-code and password handover
Compiled-only or password-locked software will not be accepted. Intellectual-property rights for the project software must be transferred to us after payment.
Required Skills
Applicants should have experience in:
* Delta PLC programming
* Delta ASDA-B3 servo programming and tuning
* Fuji ALPHA7 servo programming and tuning
* Position, speed and torque control
* Servo homing and motion sequences
* Torque-angle nutrunner systems
* Force-displacement servo presses
* Load-cell and encoder integration
* EtherCAT, CANopen and Modbus
* Delta HMI, WinCC, VB.NET, C# or Lua
* SQL database development
* Real-time graph plotting
* PDF/Excel/CSV reporting
* Industrial alarms and safety interlocks
* Machine commissioning
Experience in automotive assembly, electric nutrunners, press-fit monitoring, process-signature analysis and production traceability will be preferred.
Questions Applicants Must Answer
1. Have you developed a torque-angle nutrunner?
2. Have you developed a force-displacement servo press?
3. How will you capture high-speed curve data?
4. How will the press curve be compared with upper and lower limits?
5. Which communication protocol do you recommend?
6. Which GUI platform do you recommend and why?
7. How will cycle data and graphs be stored?
8. Can you provide remote and on-site support in Bengaluru?
9. Will you provide complete editable source code?
10. What is your milestone-wise price and schedule?
Expected duration: approximately 15 days.