PLC Application in Tape and Spray Machine and Automatic Cylinder Filling System

Tape and Spray Machine
The Machine of Tape and Spray improve engaged the substitute of an available relay and timer based control system with a PLC, with the integration and a new control program creation. The Machine of Spray and Tap used out-of-date technology, being neither maintainable nor enhance able for the abrasive products manufacture. Additionally to replace the control system of relay-and-timer with a PLC, importance was located on orderly standard practices, construction, and maintenance documentation. A complete, sequence of operation and detailed specification was built up for the new control system.

The swap over to the new control system was finished incrementally, switches, solenoids, and bringing photocells over to the new system independently though maintaining the old control. For instance, an available photocell was wired to the PLC, and the PLC next offered the input signal to the older control system. Run time was influenced for only short periods, and swap over errors were simply placed, minimizing their consequence.

The resulting transition of evolutionary the control system of Spray and Tape permitted the user to sustain productivity during this transition from older to new. During this phase there were only concise outages, something which is of major importance to mainly manufacturers.

Automatic Cylinder Filling System
In order to make automate the manual thorough process of filling gas cylinders and executing final product analysis. The cylinders were to be plugged by weight with gases predefined mixtures with standardized recipes. Furthermore, equipment was needed to watch temperature, pressure, and conditions of filling.

A system 8 bay able of concurrently filling 4 units was planned, installed, and tested at the user's site. The equipment of automation chosen included as below:
• Installation SCADA system of FIX32
• SLC503 PLC Allen Bradley
• Serial communication of BASIC module
• Scale Interface of Mettler-Toledo Jaguar
• Rotary valves of VALCO multi-position
• Thermco
• Analyzers
• Meeco Aquamatic
• Rosemont NGA

The user was initially able to fill up less than 300 cylinders daily using the manual system. The process automation enlarged plant capacity to larger than 1000 cylinders daily. Furthermore, the user was capable to decrease the operator number from 4 to 2 on a given shift enable a third shift to be working. The system also supposed the product analysis responsibility, officially carried out by the lab technician. After a year of production the user asked for the adding of automatic cylinder tracking and quality analysis records.

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