Industrial Informatics, Inc. was contracted to retrofit a leak test cell to print custom bar-coded labels based on part configuration and final test status. During the initial project planning we determined that the system was built on obsolete technologies that were prone to error and false results.

 The original machine was designed around an unsupported Wonderware interface using Microsoft Access 97 as a back-end data server for parameter storage and data collection. An Allen-Bradley SLC500 PLC executed predefined test cycles based on the parameters downloaded from the Wonderware interface. The system was sequenced with the assembly line through a DH+ (Data Highway Plus) connection to an Allen-Bradley PLC5/250 Pyramid Integrator. The test cell was no longer supported by the original manufacturer, and several changes were required maintain test accuracy and implement the automatic labeling project.

 Our solution was built around a Visual Studio interface using SQL Server Express 2005 as a stable back-end data server. The HMI uses our Conferax™ rev. 3.1 OPC communications library and RSLinx Gateway OPC Server to communicate between the Allen-Bradley SLC500 test cell PLC and the PLC5/250 Pyramid Integrator assembly line controller. The interface controls LabelView Server labeling software through a DDE connection to automatically print product labels to two Zebra thermal printers. The customer can now maintain their own interface software without the need for expensive licenses. By replacing Access with SQL Server 2005 we were able to schedule automatic data backups and prevent corrupt Access lock file errors. The entire system can be administered remotely from our Charleston location without the need for costly on-site maintenance calls.

 Request more information about this project...