Projects we have worked on
We would like to present just a few examples of hundreds of our own control systems, modernization of industrial facilities and self-designed electronic devices. Our solutions can be used in such places where reliability and high-performance play an important role.
Modernization of a bar drawing machine
Modernization of a bar chamfering machine
Automatic control system of an electroplating line
Modernization of a linear resistance welding machine
A station for laboratory resistors testing
A hard-to-start electric drive system in a paper mill
A thyristor resistance welding power and time controller in a can factory
Modernization of a bar drawing machine
As the result of automation, role of the operator is limited to put a package of steel rods on the loading table, and then just to supervise the production process.
An automated drawing machine is used for production of cold-drawn rods from a feed material in the form of rolled bars. As the result of drawing, smooth surface of the bar is obtained, as well as equal diameter over its entire length. The bar drawing machine, which was the subject of modernization, has a force of drawing of up to 50 tons.
Our work was to create a comprehensive system of automatic control, based on PLCs. As the result of automation, role of the operator is limited to put a package of steel rods on the loading table, and then just to supervise the production process. Rods are automatically supplied by the roller table conveyor that moves the material into the jaws of the hydraulic insertion unit. After that the rod is inserted into the die. The next step is to clamp jaws of the carriage, driven by an electric motor, and then drawing the rod. The finished product is transferred to a receiving stand with pneumatic-powered arms. In the bar drawing machine there are three types of drives: electric, hydraulic and pneumatic.
In this project we have done:
- design of the automatic control system,
- develop a control algorithm and programs for two PLCs,
- routing of wires of both control and power circuits (over 700mb of cables),
- installation of dozens of inductive sensors,
- fabrication and installation of junction boxes,
- fabrication of two control panels,
- fabrication of two housings containing electrical and electronic circuits,
- fabrication of the thyristor inverter for the electric DC motor 250kW which drives the carriage (the system has a continuously variable speed control and implements dependent excitation),
- fabrication of the thyristor inverter for the electric DC motor which drives the carriage back to home position,
- commissioning of the control system,
- preparation of a complete technical manual,
- training staff in the use of the control system of the bar drawing machine.
Modernization of a bar chamfering machine
As the result of automation, role of the operator is limited to put a package of steel rods on the loading table, and then just to supervise the production process.
An automated chamfering machine (called also beveling machine) is used to chamfer the ends of steel rods. Our work was to create a comprehensive system of automatic control, based on a PLC. The most important were the safety of operators, production efficiency and reliability. As the result of automation, the machine can be operated by one person only, whose role is limited to put a package of steel rods on the loading table, and then just to supervise the production process. The rods are automatically aligned and transferred by conveyor to the chamfering head, which makes chamfering. The finished product is transferred to a receiving stand. The control system was created with use of contactless components like variable-frequency drives and semiconductor relays (SSR), so the system is highly reliable. In the chamfering machine there are two types of drives: electrical and hydraulic (there are two hydraulic pressure stations).
In this project we have done:
- design of the automatic control system,
- develop a control algorithm and program a PLC,
- routing of wires of both control and power circuits,
- installation of over a dozen of inductive sensors,
- fabrication of a control panel,
- fabrication of a housing containing electrical and electronic circuits,
- commissioning of the control system,
- preparation of a complete technical manual,
- training staff in the use of the control system of the bar chamfering machine.
Automatic control system of an electroplating line
With use of the computer system, at the same time on the line can be multiple drums / hangers, each of which may be driven by a different cyclogram (technology program). We have developed software which precisely controls the line, what ensures repeatability and maintenance of proper technological parameters.
A technological line in the plating plant consists of 30 bathtubs among which drums are moved by means of two carriages. Our computer system automatically controls the carriages. As the result of automation, role of the operator is limited to move items from boxes to the loading station, and then receive the finished product. At the same time on the line can be multiple drums / hangers, each of which may be driven by a different cyclogram (technology program). With this solution optimal production of small series is possible, without the need for draining the line of drums / hangers of one technology program, prior to the start of production in accordance with another technology program. We have developed software which precisely controls the line, what ensures repeatability and maintenance of proper technological parameters, and also forces workers productivity. Visualization of the process, content of bathtubs and production statistics is implemented. The voice messages appears.
Modernization of a linear resistance welding machine
Since technological parameters are precisely maintained by the microprocessor controller, it is able to obtain identical weld over the entire length of an item.
Described linear welding machine is used for the production of air ducts. Our work was to equip the machine with a modern control system based on a PLC and a microprocessor-based thyristor power controller supplying the welding transformer. The reliability of the machine was increased thanks to the use of a reliable thyristor controller and a modern control system, as well as replacing unreliable electromechanical sensors with contactless inductive sensors. Since technological parameters are precisely maintained by the microprocessor controller, it is able to obtain identical weld over the entire length of an item. Resistance welding process can occur with continuous current or with flexible configurable intervals with no current (used in lap seam resistance welding). The operator can set the power and resistance welding time for three phases (initial, middle and final). Since the safety relay was used, safety of staff was increased. Motors were protected with the use of motor breakers. Operation of the control system can be set to automatic or manual mode. There is the ability to work with two wires (separately for upper and bottom roller) or with the same wire for both rollers.
A station for laboratory resistors testing
The station was used for laboratory testing of neutral earthing resistors of the earthing transformer used at the National Stadium in Warsaw / Poland.
On request of the leading Polish manufacturer of industrial resistors, we developed the specialized station for laboratory resistors testing. The main task of the device is to generate the output current at a specified time duration of the signal (from seconds to hours) and the duration of the delay with no current. The shape of the generated current can be rectangular or sinusoidal, frequency from 40Hz to 400Hz. Depending on the resistance of the tested resistor, the generated current can be up to 1000A, and the voltage up to 200V. The laboratory station allows the examination of the resistor's structure due to the increase of its temperature during the test. As part of the project we built an inverter power circuit, an electronic circuit of the microprocessor interface and dedicated software. The inverter contains the block of thyristor rectifier and the generator based on IGBTs transistors. The microprocessor interface provides communication between the computer and the power circuit, and it also includes a DDS generator for output signal. Dedicated software allows visualization of set current, measured current, voltage and temperature. Detailed reports, graphic waveforms are able to print. The resistor test can be performed in two modes:
- manual, in which the operator can set current, frequency and waveform,
- automatic, in which the testing process runs automatically, based on the previously made settings.
The station was used for laboratory testing of neutral earthing resistors of the earthing transformer used at the National Stadium in Warsaw / Poland.
The device is used to test the grounding resistors, forcing resistors, braking resistors for inverters, loading resistors, start-up resistors for cranes, traction resistors and resistors for hard-to-start.
A hard-to-start electric drive system in a paper mill
In cooperation with the leading Polish manufacturer of industrial resistors, we developed and implemented an automatic resistance starter for a wound-rotor motor, driving the pulp mixer, where a wastepaper is grinded in the paper and cardboard factory. The drive system is a hard-to-start one. The device uses our microprocessor controller, which main purpose is to continuously measure the actual value of the frequency of the current induced in the rotor winding and switching the appropriate resistance sections.
A thyristor resistance welding power and time controller in a can factory
During modernization of machine for resistance welding of longitudinal seams of cans, we created the specialized microprocessor thyristor resistance welding power and time controller. The new device provides precise triggering of the welding cycle, synchronized with the front of the can. Our solution eliminated the problem of cans leaking due to not properly welded initial part of longitudinal seam, which took place in the past with the old controller. Since technological parameters are precisely maintained by the microprocessor controller, it is possible to obtain identical weld over the entire length of a can.
