Below are summaries of a number of applications that PJC Systems have completed, to give an outline of the type of work we undertake
To find out more about a specific application, and to view photographs and graphics screens of the project, please click on the appropriate link.
There were several aspects to this project
Replace the Silo Panel with a new one which will cater for 2 silos
Replace the PLC/HMI Panel - to be able to cater for the new equipment
Move PLC & HMI panel out of the newly designated Atex area
Add the feed to 2 new production lines (added during contract)
The control system, being nearly 25 yrs old, now had obsolete components as the central part of the system. Both the PLC and SCADA system (not as old) were no longer supported. It was, therefore, decided to upgrade both to something more current which should be supported for many years to come. The work was carried out over the Christmas shutdown.
A number of years ago we put a system in for this customer to feed PVC Resin from two silos to a single mixer. The customer now wanted to add a third Resin Silo, and to feed all three silos to the existing mixer, and two others. There was clearly the potential to need to isolate one (or more) of the mixers for maintenance, but keep the others running. For this reason we had to completely re-configure the system so that the Silo Panel became the master of a networked system.
This project was to feed maize (coarse or fine) from storage silos, via weighers, to a number of mixers. Here it is mixed with a number of minor additives (added by hand) before being extruded to form products such as Onion rings, Bacon Frazzles etc. The introduction of this system removes the need for the operator to tips tonnes of material per shift from 25kg sacks.
We were approached by a local company looking to develop the next generation of clad welding machines for their business. They were looking for the basis of these machines to be plc control. The plan was to build a prototype machine, thoroughly test it in a production environment, then build eleven production machines. PJC Systems were pleased to be part of the development process.
PJC Systems secured the contract to control everything from:
delivery of raw materials to the bank of silos
transfer of materials from the silos to all three mixing plants
control of mixer HSB7
transfer of blended material from all three mixers to internal day bins
transfer from day bins to compounders, and back to compounded day bins
transfer from day bins to silos
In 1997, PJC Systems were employed to control the new Mixer no. 2. The remit was to set up the control such that the Resin Silos (raw material) and Dry Blend Silos (finished product) could be shared by both mixers in the future. PJC Systems configured the system so that all the items of plant which were to be common to both Mixers were controlled by a "common controls" panel, which, in turn, communicated with each mixer's own control panel via MelsecNet/B. All the plcs were Mitsubishi AnS series, and the graphics were (originally) Mitsubishi AMING, running under DOS. In 2001, PJC Systems upgraded the graphics to Mitsubishi MX2000 running under Windows, but left the rest of the control the same. The factory manager could monitor both mixers from his office, but couldn't control either of them. Batch data was logged to the factory manager's computer. In 2004, PJC Systems also took control of the additives system which fed both of the mixers, added it to the existing plc network, and integrated it with both mixing plants
This application deals with the control of automatic train washing plants. We have grouped together a couple of plants; one in Ireland, the other in India. The projects involved panel design, plc, & hmi software, and commissioning, but the panel build and site wiring were by others.
Key components:- Mitsubishi AnS series PLC, Beijers E/MAC series hmi's
This application deals with the control of lean phase pneumatic conveying systems feeding powder from a number of sources to a number of extrusion machines. We have grouped together a number of similar systems, te largest of which feeds 35 extruders from 38 different sources. The projects involved panel design, panel build, plc, and hmi application software, and commissioning.
Key components:- Mitsubishi AnS series PLC, Beijers E/MAC series hmi's
This application deals with the control of a rig which tested the integrity of components, evacuated them to a very low atmosphere, then pressure filled them with a liquid. The project involved circuit design, plc and hmi application software, and factory testing
Key components:- Mitsubishi Q series PLC, Beijers E910 hmi
This application deals with the control of three PVC mixing plants at the same site. The project involved panel design, plc, and SCADA application software, and commissioning. All the systems have also been modified since their original installation.
Key components:- Mitsubishi AnS series PLC, Mitsubishi IPC running MX4 SCADA, a number of the Customer's comupters running MX4 SCADA software
The Lime plant is controlled via a plc based control system, with it's own operator interface (hmi), giving access to all necessary functions, adjustments, and notification of alarm conditions. Water and lime are accurately added to two mixing tanks (on demand), which mix the lime into a slurry. This batch of slurry is then transferred to the slurry tank, which is of a much higher capacity.
Key components:- Mitsubishi Q series PLC, Beijers E1071 hmi, ethernet, Mitsubishi E540 series inverters
This application deals with the control of all the materials handling within an entire factory. The project involved panel design, plc, SCADA and hmi application software, and on site commissioning.
Key components:- Mitsubishi Q series PLC, Mitsubishi IPC running MX4 SCADA, Beijers E1101 hmi, a number of Beijers E300 hmis, ethernet, Inverters, Red Lion Data Station
This application deals with the control of a Mixing Plant producing Foam for extruding as an inner for soffits, cladding etc. The project involved panel design, plc and SCADA application software, and on site commissioning.
Key components:- Mitsubishi Q series PLC, Mitsubishi IPC running MX4 SCADA software, ethernet, Red Lion Data Station
This application deals with the control of a Carousel Rotational Moulding Machine. The project involved panel design, plc and hmi application software, testing at the customer's works, and on site commissioning.
Key components:- Mitsubishi Q series PLC, Beijers E1151 hmi, ethernet, CC-Link, Inverters, Red Lion Data Station
