Other Projects
Rdh Plant for J K Corporation, Orissa
RDH Rapid displacement heating is the process used in paper manufacturing. In the above plant main process is controlled by Fischer Rosemount’s Provox DCS. GE- Fanuc Series 90- 30 PLC with 500 I/Ps & 160 O/Ps were used to check all permissive and interlocks. After receiving command from DCS, PLC checks for permissive & interlocks to start particular output. In case of failure of any interlocks PLC switches off the output. Also stat us of all inputs are given to DCS on serial line (Modbus RTU, RS 485)
Injection Moulding Machine at Datar Switchgeat ltd, Nashik
GE-Fanuc Series 90-30 PLC with touch screen Operator interface unit was used for complete control FahrBucher Injection molding machine.All the necessary parameters as mould closing & operating speed, injectio n speed and pressure, plasticizing speed and pressure were programmable from OIU. Position of mould, injection unit and ejection was interfaced with PLC through analog input. Temperature of mould was also controlled by PLC Pressure & Speed of various components such as mould, injection unit, ejection, s ide con piston etc, were controlled through analog output to proportional value of Rexroth.
Robotics Material Handling at GKN, Faridabad
Auto loader Robot, in this system GE Fanuc Series 90–30 PLC with two axes, Axis Positioning Module and HMI unit with Servo system and VFD are used.There is various Position for Robots to pick up components and load the components in the machine for internal girding.All positions, speed, accelerations related to all position are programmable through HMI unit. The specialty of system is auto correction of girding position for every cycle. Here two feedbacks one is from Servo Motor encoder and second is from girding wheel position encoder, using this PLC calculation correct grinding position. All manual operations are done through HMI unit. All alarm related to Robotics displayed on HMI unit.
DG Set Controller
Executed two projects at prestigious customers M/s Duracell and KBL wadi; Project involves controlling distribution and switchover as per demand among 4 DG and Electricity board supply. Also involves management of po wer and optimum user DG sets. Projects involve 300 plus I/Os including analog I/Os.
Conveyor Synchronization
Customer
Bajaj Auto Ltd
End User
Bajaj Auto Ltd.
Supplied on
May’2002
Location
Waluj, Aurangabad
Commissioned on
Jun’2002
Application Requirement
Bajaj Auto Ltd. is a leading company in auto industries. They manufacture two and three wheelers. They produces 2000 two wheelers and 500 three wheelers per day
For assembly of the vehicles, there are two conveyors. One bottom conveyor for vehicle movement and one Overhead conveyor for part to be assembled on it. Overhead conveyor was extended to stores to load assembly Components in bin. Multiple operators are doing assembly at a time. Each operator assembles 2 -3 parts on vehicle. Both conveyors should run in synchronization so that bins should never hit vehicle. The plant is running 2 or 3 shifts.
Distance between bin and vehicle is about 15 cm. So even small difference in synchronous speed could have cumulative effect and bin may hit vehicle
Customer Expectations
Low cost, reliable system. Because of some problem any operator can stop the system. So even on multiple stoppages and re-starts, conveyors should not lose synchronization and distance between bins and vehicle should not change
VSAS Solution
VSAS has Engineered and Commissioned VFD, PLC & HMI system for the above requirements. VSAS Solution was based on GE Fanuc Versamax Micro PLC OIU Operator interface unit to set production speed Danfoss VTL 5008 VFDs with Synpos Card
Benefits
Increase in production by about 20%. More operator comfor
Machine Utilisation and Monitoring System
Customer
Bajaj Auto Ltd
End User
Bajaj Auto Ltd
Supplied on
Feb’2001
Location
Aurangabad
Commissioned on
April’2001
Application Requirement
System consists of 90-30 PLC for synchronization, Versamax 28 pt micro for each m/c and Cimplicity Scada package,Control system was designed to perform
Production planning,Production of Man & Machine in CELL,Machine can be idle but man cannot, Shift wise production report, Operation of multiple Cell’s through single station, Factory server connectivity
Customer Expectations
Increase production rate by increasing efficiency of operator, watch response of planned production & actual production, trace out reasons of m/c breakdown, decrease down time of m/c.
VSAS Solution
VSAS has design the system with 90-30 PLC as Master for synchronization of CELL activity & data collection, one micro per m/c for Event recording, Cimplicity SCADA Package is for event logging, VB s/w is for production planning & reports.
Benefits
- Low cost configuration
- More additional features than Kawasaki POP system
- Easy to maintain
- Remote monitoring of production report
- Automatic Production analysis
- In built POKAYOKE features
- Automatic E-MAIL generation for programmed event
Electroplating Transporter
Customer
Bajaj Auto Ltd
End User
Bajaj Auto Ltd
Supplied on
Nov’99
Location
Waluj, Aurangabad
Commissioned on
Nov’99
Application Requirement
Bajaj Auto Ltd. is a leading company in auto industries. They manufacture two and three wheelers. They produces 2000 two wheelers and 500 three wheelers per day. For electroplating plant need of PLC.
The plant is having four transporters which travel over thirty four tanks. The PLC is housed in IP65 Panels due to the vapors of Tri-Nickel Chromium. As the Transporter travels the cables of the inputs and outputs also gets stretchedor compressed.To avoid this, genius blocks has been used, which has been installed in the panel placed over the transporter.
- Control system was defined to perform
- Control of transporter motors
- Control of washing solenoid valves
- User friendly supervisory system for OI & reporting, alarm Management, Data Logging.
Customer Expectations
Low cost, reliable PLC system. To avoid the cables which are coming to main panel earlier, the all cable has to be replaced every year because due to the transporter travel from one tank to another the cables gets damaged. The HMI shall include quality graphics, exhaustive reporting & trending features.
VSAS Solution
VSAS has Engineered and Commissioned PLC & HMI system for the above requirements.To sort out cable proble m VSAS has installed Genius Blocks in the transporter panel which is paced over the transporter. VSAS Solution was based on 1)CPU System 2)I/O System 3)Communication System 4)HMI
Benefits
- Cost effective versatile communication system
- Easy to maintain panels
- Less downtime as immediate fault annunciation
- User friendly graphics & HMI features
- Historical & real time data for analysis
Robotics Automation for Glue Dispensing System
Customer
Precision Automation and Robotics Industry (PARI)
End User
Maruti Udyog Ltd, Gurgaon,Haryana
Location
Haryana
Application Requirement
System consists of 96 DI/DO with HMI where the various positions of robot were decided by PLC and Servo System, Control system was designed to perform, To control the positions of robot to pick up the component,To load the component in the machine for internal girding, With the help of HMI parameters such as positions, speeds, accelerations are programmable
The plant is having four transporters which travel over thirty four tanks. The PLC is housed in IP65 Panels due to the vapors of Tri-Nickel Chromium. As the Transporter travels the cables of the inputs and outputs also gets stretchedor compressed.To avoid this, genius blocks has been used, which has been installed in the panel placed over the transporter.
- Control system was defined to perform
- Control of transporter motors
- Control of washing solenoid valves
- User friendly supervisory system for OI & reporting, alarm Management, Data Logging.
Customer Expectations
PLC system with accurate control of positions of the Robots.
VSAS Solution
VSAS has design the system with series 90- 30 PLC and two axis positioning module and servo system. The specialty of the system is auto- correction of girding position for every cycle.Two feedbacks one from encoder and second from girding wheel position encoder was taken. Using this two encoder, feedback, accurate position is decided.All manual operations were done by HMI.Alarms related to Robot were displayed on HMI
Benefits
With the help of axis positioning module accurate position of Robot were controls.Immediate parameter setting in case of manual control
K-Line Transfer
Customer
Bharat Forge ltd, Pune
End User
Bharat Forge ltd, Pune
Supplied on
Oct’99
Location
Pune
Commissioned on
June’99
Application Requirement
BHARAT FORGE LTD has got Transfer Line where various operations were performed on job.There are twenty operating stations in this transfer line.System consists of 640 i/p and 400 o/p where parameters can be changed with MMI and process can be viewed with
the help of SCADA monitoring system.Control system was envisaged to perform Control of various machines such as Milling m/c , Horizontal boring m/c , Drilling m/c. Various alarms were generated if failure occurs in the process. Centralized control from main control room.User-friendly supervisory system for OI & reporting.
Customer Expectations
Low cost, reliable PLC system. The HMI shall include quality graphics, exhaustive reporting & trendi ng features.
VSAS Solution
The VSAS has done the complete Erection and commissioning of the K-Line Transfer as per the requirement of BFL, Pune.
Benefits
- Cost effective versatile solution.
- Easy to maintain panels.
- Less downtime as immediate fault annunciation.
- User friendly graphics & HMI features.
- Historical & real time data for analysis.
Burner Management System of Walchandnagar Industries Ltd
GE-Fanuc Series PLC and Operator Interface control burner Firing System. Burner Management System is consisting of Air Purging, Bio gas Firing, Oil Firing, Bio gas purging and Oil Gun Scavenging with Audio-Visual Alarm Indications. After the Interlocks for the oil Gun Scavenging with Audio-Visual Alarm Indications. After the interlocks for oil firing has been satisfied and start command is given to oil firing the pilot flame should come out within prede termined time, if not the solenoid valve for oil firing must be closed this critical application is satisfactorily done through GE-Fanuc PLC. All the timers’ values of the process can be viewed or modified through the operator interface.