PLC and HMI Projects

Programmable Logic Controls (PLC) - programmed with ladder logic and structured text instructions to perform simple, repetitive tasks with simple inputs and outputs. Very limited decision making and usually implemented with complex safety backups when operated near humans.

Human Machine Interfaces (HMI) - easy to interact with human operators to perform some control over of PLC based automation. These include a digital, graphics based display and touch screen for programmable on-screen controls. Most HMI systems are computer controlled and have their own programming language.

Printing press controls

Mitsubishi FX, FX2N controllers controlled by serial interface
Rockwell PLC/5 controllers controlled by DataHighway Plus network
Beckhoff CX5010, CX8190 controllers controlled by TwinCAT3 network
Maple System HMI controlled by Ethernet network

Liquid Immersion Cooling controls

Beckhoff CX5140 controllers controlled by TwinCAT3
Aveva Indusoft HMI platform operating on PLC

PLC Factory controls

Beckhoff CX5140 controllers controlled by TwinCAT3 networks
Aveva Indusoft PC based HMI controlled by TwinCAT3 networks

Printing press controls

Mitsubishi FX PLC - all of these implementation are serial based commands, no digital output. simple timed response when inputs are activated. Inputs are usually press speed encoders and digital input commands from higher level computers. Outputs are usually pneumatic actuators. These were programmed with ladder logic.

Rockwell PLC/5 PLC - implemented as complete press control systems, programmed with ladder logic, architecture is organized in special memory sections called pages. each page had special functionality for the press controls. GMI usually wrote to organized cells inside a page to manipulate the ink sweep and dampening controls on the printing units. Communications to these PLC was through a special ARCnet interface call DataHighwayPlus. It required a special electrical interface to provide data to this communications network. There are over 15 press configurations implemented for this type of press controller PLC.

Beckhoff CX5010 and 8190 PLC - implemented as ink sweep and dampening press control systems, programmed with structured text logic, architecture is organized in special memory sections called MODBUS. MODBUS is implemented as a TCP/IP protocol. GMI usually wrote to organized cells inside an addressing system to manipulate the ink sweep and dampening controls on the printing units. Communications to these PLC was through a MODBUS command system, with PLC being a master of the PLC data and all other computers were functioning as slaves to change the PLC. The CX8190 PLC required a Profibus connection to other parts of the main press controls.

PLC based color ink controller – Beckhoff GMBH PLC (new product line - 2016 to 2020)

· CX5010 CPU – x86 Win CE

· CX8190 CPU – ARM

· IEC 61131-3 (Structured Text) programming

· TwinCAT2 & 3

· MODBUS Server software

· MODBUS Master and Slave protocols

· PROFIBUS – EL6731 slave interface

Summary – many unique controls for each color in printing press. Coarse and fine controls to ink processes. Analog to Digital interfaces, encoded positioning, MODBUS master to PC based control system. Mark was responsible for all of the 30+ PLC control code modules and variable maps.

30K LOC of structured text (PLC)

HMI touch displays - Maple Systems HMI (new product line – 2017 to 2019)

o Maple Systems HMI5040B 4.3” TFT

o (480 x 272 Pixel Resolution, Cortex A8 600 MHz CPU 32 bit, 1 Ethernet, 1 Serial Port + 1 USB Port)

o PLC – MODBUS TCP mapping to PLC master

o Maple Systems EZware Plus GUI environment

Summary – printing press operator controls for color ink settings. Up to 15 options and settings to control. Mark was responsible for controls/data handling macros and GUI.

2K Total LOC – special Maple GUI programming macros with custom GUI bitmaps.

Mitsubishi PLC example

AB PLC/5 example

Feature enhancements of existing products above(2023 – 2024)

Printing press operator console – color control (OCU3)
Servo Power Unit (SPU)
HMI touch displays (HMI)
Color ink metering actuator (servo)
PC controlled in-press spectrophotometer (transport and measurement assembly)

Liquid Immersion Cooling controls

TMGcore sold products for HPC platforms using Liquid Immersion Cooling, both Single Phase and Two Phase. Single phase was a crowded market already and they had patented a two-phase product; much more expensive, with mediocre performance improvement – Mark was hired to support Controls/Data Monitoring with Beckhoff CX 5140 PLC plus HW slices – monitor RTD, flow, pressure – record data. Using Beckhoff Visualizations for Local control is LCD monitor with touchscreen. In Dec 2021, TMGcore investors decided it needed to make some money, so management decided to go after the crowded single-phase market. They openly borrowed from their competitors; product designs and customer base. Everyone was convinced that the Crypto-currency market was going to be the next IT craze and jumped in with both feet.

4U cooling tank controller and display

4U cooling tank controller and VFD pump

single phase PLC controller project

Two phase PLC controller product (enclosure)

Crypto miner tank

Crypto miner power control display

Crypto miner farm

PLC Factory controls

Beckhoff CX5140 PLC - automated product cleaning, inspection, testing, storage, shipping. The types of PLC are used for conveyor motor controls, inspection and cleaning workstations with robot manipulators, product ID scanning, machine vision inspection for dimensions, robot control for loading product into/from ARS, robot controlled conveyor to conveyor product movement, robot controlled product insertion into packaging, robot controlled palletizers and wrapping systems. These PLC were connected together and controlled via Beckhoff TwinCAT network. The programming was performed with Structured Text PLC logic.