Ignition and PLC Programming Upgrades -
Control Solutions by Cleveland Automation Systems
Introduction
Enhancing Control and Efficiency with Tailored Automation Solutions
Cleveland Automation Systems® (CAS) partnered with a long-term client to modernize a limited plant-level control system that was jeopardizing their operational efficiency. The existing setup lacked advanced PLC programming and a Human Machine Interface (HMI), preventing real-time adjustments to timers, sensor inputs, and production parameters. These deficiencies ultimately led to inefficiencies, such as increased downtime, and operational disruptions. At the end of the day, operational inefficiencies of this kind are something we see a lot of at CAS, which is why we know that these issues also threaten both productivity and profitability.
Supply chain disruptions, delays in customer deliveries, and missed production targets erode client trust and market competitiveness. Over time, these inefficiencies can drive up operational costs, reduce profitability, and limit your organization’s ability to scale effectively. All of this points to need for targeted, long-term automation solutions. And that’s where we come in.
At CAS, we specialize in tailored automation solutions that not only overcome immediate operational challenges, but also drive measurable long-term results. For this client, our PLC Programming Upgrade featuring Rockwell Automation CompactLogix PLC, integrated pneumatic stops, and Inductive Automation’s Ignition platform with an Onlogic Panel PC streamlined production by 15%, reduced downtime by 45%, and allowed for reduction of two operators to run the line. Beyond fixing inefficiencies, this upgrade laid the groundwork for scalable growth, empowering the client to adapt quickly to future demands and easily integrate new technologies. The result? Improved productivity, consistent product quality, and a smarter future-ready production line.
To solve these challenges, CAS upgraded the control system by installing a Rockwell Automation PLC to manage conveyance and pneumatic stops and integrate with OEM equipment. CAS also deployed Inductive Automation’s Ignition platform as the HMI, using an Onlogic Panel PC, allowing operators to access and control real-time data. The improved system significantly enhanced operational efficiency, reduced downtime, and increased production accuracy, leading to substantial cost savings and better product quality. This upgrade not only resolved the client’s immediate issues but also set the foundation for future scalability and growth.
The Challenge: Limited Control Capabilities Stifle Production
The client faced several critical challenges due to their outdated control system:
- Limited Control Capabilities: The system featured basic PLC programming but lacked advanced functionalities necessary for optimal control.
- No Human Machine Interface (HMI): Without an HMI, operators could not adjust timers, control sensor inputs, or make real-time changes to the production line.
- Operational Risks: These limitations led to inefficient production processes, increased downtime, and disruptions that hindered the company’s ability to meet production targets.
- Product Variation: The system ran multiple product SKUs of different shape and color, requiring the system to dynamically change settings such as sensor sensitivity, debounce timers and paint color.
The CAS Solution: Comprehensive PLC Programming and Ignition Integration
CAS conducted a detailed site assessment to design a comprehensive solution addressing the client’s production challenges. The final upgrade included advanced PLC programming, intuitive HMI integration, and centralized control for streamlined operations.
Highlights of Our Solution):
- Advanced PLC Programming: Enhanced system functionality with improved monitoring, control, and integration across the production line.
- User-Friendly HMI: The Ignition platform enabled operators to visualize, manage, and adjust processes in real time, improving overall usability and efficiency.
- Seamless Integration: CAS incorporated pneumatic systems and existing OEM equipment into the centralized control system, ensuring synchronized operations.
- Dynamic Recipe Changes: Fully configurable and adjustable settings that could be adjusted on the fly to account for product variation.
To address the client’s need for a more sophisticated control system, CAS implemented a comprehensive PLC Programming Upgrade. The solution integrated advanced controls, an intuitive HMI, and centralized management of various production components. CAS aimed to provide the client with an efficient and reliable solution that streamlined operations, reduced manual intervention, and minimized downtime, ultimately improving productivity and allowing for future scalability.
Advanced PLC Programming
CAS provided Controls Engineering Services, including upgrading the existing PLC programming system and deploying Inductive Automation’s Ignition platform. This system included custom-built AOIs to adjust IO-Link enabled devices via a recipe change. The IO-Link sensors would read back millimeter distance measurement, which would adjust based on the product size. This functionality allowed for automatic identification of product size and part variation. Pneumatic stops were added to control products in high backup areas. Line load balancing was also implemented to alleviate product accumulation in bottleneck areas. What used to require two operators continuously destacking and holding product back by hand was eliminated, allowing personnel to be used in better suited locations. This upgrade introduced advanced control functionalities, enabling better integration across systems and offering the client an improved user experience.
User-Friendly HMI
We then specified and installed an Onlogic Panel PC equipped with the Ignition Vision Client to enhance the PLC Programming Upgrade. Cleveland Automation Systems deployed a standardized HMI interface. Our interface provides a full suite of Auto and Manual controls for all actuators, inputs and outputs. This also includes a full Alarm List and Fault History. Logging alarms and faults is crucial to allow on-site maintenance and our remote team to diagnose any issues that arise. Implementation of the HMI allows operators and management to have a visual display and control of the system. Prior to this, only an automation technician with a PC connected to the system could diagnose and control the production line. This HMI allowed operators to monitor operations in real time, access critical data, and control various processes, resulting in a seamless production flow and increased overall efficiency.
Seamless Integration
CAS designed and installed pneumatic cylinders to stop products on the production line. The cylinders, controlled via the upgraded PLC programming, were essential for flow control and load balancing, preventing bottlenecks and ensuring smooth operations. Additionally, we integrated OEM equipment, including paint booths and ovens, into a centralized PLC system, streamlining data collection and enabling operators to manage their entire production line from a single interface for improved efficiency.
Requirements and Specifications for PLC Programming Upgrade
To meet the client’s needs, the project focused on several critical requirements:
- Flow and Traffic Control: The PLC programming allowed for precise monitoring and control of product flow along the conveyor line.
- Strategic Stopping Mechanisms: CAS integrated mechanisms to stop products at strategic points, preventing backups and optimizing the flow.
- Pressure Alleviation: The upgraded system reduced line pressure at critical points, ensuring a smooth production process and mitigating risks.
- Adjustable Parameters: The client gained the ability to adjust pneumatic stop durations, entrance/clear locations, and movement timing thanks to flexible PLC programming.
- Visual Representation: Operators gained a visual representation of the production line, improving monitoring capabilities through the integrated HMI and PLC programming.
Hardware for PLC Programming Upgrade
- Allen Bradley CompactLogix PLC: Provided the robust control necessary for conveyance systems and seamlessly integrated with other components.
- Onlogic Cinoze Panel PC: Served as the HMI, running Ignition Vision Client, and significantly enhanced the usability of the PLC programming.
- SMC EX600 Ethernet/IP Valve Banks: Managed the pneumatic cylinders that controlled product stopping and flow on the production line.
- IFM IO-Link Blocks and Sensors: Enabled precise data collection, which is critical for effective monitoring and integration within the PLC programming upgrade.
Featured Industry Partner: HH Barnum – Provided the essential hardware components and helped ensure their seamless integration.
Software for Enhanced PLC Programming
Outcomes and Benefits of the PLC Programming Upgrade
The upgraded control system, featuring enhanced PLC Programming, significantly improved the client’s operational efficiency, reduced downtime, and boosted production accuracy. Real-time data access and control through the new HMI empowered the client to optimize their production processes, leading to cost savings and superior product quality. The upgraded system effectively addressed existing challenges while positioning the client for future scalability and growth.
Key Positive Outcomes:
- Increased Scalability: The new control system accommodated production demands better, allowing for more versatility and operational flexibility.
- Reduced Downtime: Operators could make real-time adjustments via the HMI, reducing setup times and increasing production uptime.
- Improved Product Quality: Enhanced control over production parameters led to higher-quality products, minimizing inconsistencies.
- Future-Proofing: With advanced PLC programming, the system has become more adaptable to future technological advancements, such as integrating additional automation tools or predictive maintenance software.
Enhance Your Production with CAS’s PLC Programming Solutions
At CAS, we wake up every day with the goal to help our clients increase productivity, improve system accuracy, and achieve greater operational control. If your business is facing similar operational inefficiencies with outdated control systems, particularly in PLC programming, explore our Engineering Services services and see how Cleveland Automation Systems can help modernize your operations.
Ready to Modernize
Your Production Line?
Contact Cleveland Automation Systems to explore how our Ignition and PLC Programming Upgrades can revolutionize your processes. Let’s discuss your unique challenges and engineer a system that ensures consistency, efficiency, and scalability.
About the Author: Rylan Pyciak
Rylan Pyciak, CEO of Cleveland Automation Systems®, is a Systems and Control Engineering graduate from Case Western Reserve University. With expertise in PLCs, robotics, and industrial engineering, Rylan leads CAS in delivering innovative automation solutions. Passionate about mentoring future trades professionals, he combines technical knowledge with a commitment to fostering sustainable growth in manufacturing.