PLC Programming Logic Refinement for Manufacturing
Budget: $1,500 – $3,000 USD
To whom it may concern,
Tandem Products, Inc. is a cast urethane company actively engaged in increasing automation within our manufacturing facility. As part of our manufacturing engineering team, I am seeking external expertise to refine our PLC programming logic.
Our initial attempt at developing the programming logic was largely successful, and through this process, we've gained valuable insights. We now have a clear and defined direction for the next phase of development, which is why we are reaching out to you.
The ultimate objective is to enhance efficiency by giving computer control over the daily calibration process (which involves maintaining very specific liquid ratio requirements) and the valve/switch sequences. This will simplify operations and improve accuracy.
Current PLC Hardware Specifications:
• PLC: IMO XGB XBC-DN32U
• HMI Controller: iView Advanced HMI Controller, Model IV207M-SEAP, Version V1.5-2.1-0SA 2145
Project Scope:
• Tandem Products, Inc. will provide a detailed flowchart to be used by the programmer for building the ladder logic.
• The ladder logic program for our IMO PLC and HMI Controller is to be utilized on Ten different pouring machines.
• The system needs to accommodate Eighteen formulations (Fourteen active, with Four blanks reserved for future additions).
o All formulations share the same input categories.
o Nine formulations utilize a 3-equation system to calculate target instantaneous input Hz for three material pumps.
o The remaining nine formulations utilize a slightly different 3-equation system to calculate target instantaneous input Hz for three material pumps.
• We would like to improve our touchscreen continuity to optimize the system's operations for Operators, Maintenance, and Manufacturing personnel.
• All formulations involve three main components and a flushing agent:
o Heated Material (HM): Transferred using a pump.
o Unheated Material (UM): Transferred using a pump.
o Dye/Colorant: Transferred using a pump.
o Flushing Agent: Transferred at the end using air pressure.
• The ratio of heated to unheated material must be precisely controlled, with a maximum allowable variance of 1.5% from the target.
• Tank liquid level determination will be performed using pressure differential measurements at the top and bottom of the tank, applying the formula P=ρgh.
• Min/Max values for flow, temperature, and pressure inputs will be linked to an indicator light affixed atop each machine:
o Yellow Light: Indicates values are outside the optimal window but allow continued operation.
o Red Light: Indicates a critical failure, requiring the computer to immediately stop all processes.
We are seeking a qualified partner to collaborate with us on this critical automation upgrade. Please let us know if you require any further information to assess this project.
Sincerely,
Tandem Products, Inc. is a cast urethane company actively engaged in increasing automation within our manufacturing facility. As part of our manufacturing engineering team, I am seeking external expertise to refine our PLC programming logic.
Our initial attempt at developing the programming logic was largely successful, and through this process, we've gained valuable insights. We now have a clear and defined direction for the next phase of development, which is why we are reaching out to you.
The ultimate objective is to enhance efficiency by giving computer control over the daily calibration process (which involves maintaining very specific liquid ratio requirements) and the valve/switch sequences. This will simplify operations and improve accuracy.
Current PLC Hardware Specifications:
• PLC: IMO XGB XBC-DN32U
• HMI Controller: iView Advanced HMI Controller, Model IV207M-SEAP, Version V1.5-2.1-0SA 2145
Project Scope:
• Tandem Products, Inc. will provide a detailed flowchart to be used by the programmer for building the ladder logic.
• The ladder logic program for our IMO PLC and HMI Controller is to be utilized on Ten different pouring machines.
• The system needs to accommodate Eighteen formulations (Fourteen active, with Four blanks reserved for future additions).
o All formulations share the same input categories.
o Nine formulations utilize a 3-equation system to calculate target instantaneous input Hz for three material pumps.
o The remaining nine formulations utilize a slightly different 3-equation system to calculate target instantaneous input Hz for three material pumps.
• We would like to improve our touchscreen continuity to optimize the system's operations for Operators, Maintenance, and Manufacturing personnel.
• All formulations involve three main components and a flushing agent:
o Heated Material (HM): Transferred using a pump.
o Unheated Material (UM): Transferred using a pump.
o Dye/Colorant: Transferred using a pump.
o Flushing Agent: Transferred at the end using air pressure.
• The ratio of heated to unheated material must be precisely controlled, with a maximum allowable variance of 1.5% from the target.
• Tank liquid level determination will be performed using pressure differential measurements at the top and bottom of the tank, applying the formula P=ρgh.
• Min/Max values for flow, temperature, and pressure inputs will be linked to an indicator light affixed atop each machine:
o Yellow Light: Indicates values are outside the optimal window but allow continued operation.
o Red Light: Indicates a critical failure, requiring the computer to immediately stop all processes.
We are seeking a qualified partner to collaborate with us on this critical automation upgrade. Please let us know if you require any further information to assess this project.
Sincerely,