Laser Control System
Adsyst successfully provided an innovative laser control system for a leading worldwide solutions provider.
The Background:
Our client provides some of the world’s most advanced, technology-led defence, aerospace and security solutions and employs a skilled workforce of some 83,100 people in over 40 countries. Our client required PLC and SCADA modifications and Laser/ sensor automation for a Maskant Line Transporter. This work was to overcome accuracy and reliability issues with the transporters on their Maskant automation line.
The Challenge:
The existing position control of the Maskant line transporters uses a set of limit switches and proximity sensors that were used for slowing down the transporter before coming into position and then confirming the final position reached. The location of the existing limit switches/proximity sensors were difficult to maintain in their current locations/positions. With an increase in production, these issues were becoming more apparent.
The Solution:
Adsyst changed the current positioning system to use a laser positioning control system which offers a lot more accuracy, improves reliability and reduces maintenance issues.
Adsyst installed the new laser-controlled transporter positioning system which required modifications to the existing SCADA (Wonderware InTouch) system, Allen-Bradley PLC5/80 and ICA section. A new Siemens S7-1500 PLC (exact type is S7-1515-2PN) was fitted in the existing ICA section, together with two 16-way digital output cards and one 16-way digital input card, plus a new EthernetIP to ProfiNet converter, and a new managed switch. The new S7-1500 PLC handles the data from each laser and controls the position of the slide mechanisms which moves the lasers into one of three positions. Several new SCADA pop-up screens were generated to show the laser monitoring system in the running condition, providing setpoint entries, and mode selections and providing new trending / logging of each Laser’s position. During the running of the line, additional alarms have been added to the existing SCADA for several laser and slide mechanism failure/fault annunciations. The SCADA also has a new Kepware communications driver (OPC s/w license) installed to enable it to talk to the new S7-1500 PLC.
The Results:
Adsyst successfully deployed during the Christmas maintenance shutdown period, with our client now having a more accurate, faster and more reliable control system. The system is now a supportable resilient process that ensures the highest machine up-time. Meeting the criteria and exceeding customer expectations throughout the project lifecycle, Adsyst is proud to have been part of such a beneficial project.
