Product details
Vendor: Flexible Electronic Systems
Product name and version: PCI_BM-DP PC Plug-in card Vers. 2.2; WinPanel+ WinSPS software
Tel: (011) 975 7000
e-mail: [email protected]
URL: www.satool.com
General
Q: What industry (eg mining, food and beverage, automotive etc) is the PLC being applied in?
A: The PLC is being applied in a robotic mesh welder build by Clifford Engineering to manufacture a wide variety of welded mesh products.
Q: Describe the application briefly giving a description of any existing control systems, any previous PLC system that was in place etc. If relevant describe the switchover from the previous system.
A: The application was previously using a Mitsubishi PLC. We then changed to the Bosch CL200 and finally to the PCL PCI card in a Bosch IPC_2 industrial PC. This was done to accommodate the ongoing development and expansion in the equipment and to have the flexibility that the robot required, adapting the basic machine to the individual needs of the client.
The interface is done in such a way that the customer can easily change the application according to his client's demands, by entering the parameters in a Windows environment.
Q: Who did the system installation/integration?
A: The customer performed the installation and the programming, along with Clifford Engineering, the OEM.
Q: Approximately how many man-hours did the installation/integration take?
A: The hours required for the installation differ for each application, but to put it into perspective, we complete four machines every month.
Q: How is the after-sales support handled (eg remote-dial-up, e-mail, Internet access etc)?
A: There have been very few occasions where any after-sales support was actually warranted. When the customer did need some technical support or had any enquiries, he says, "I just phoned up Guenter Schmitz, the Director of Flexible Electronic Systems, and he would personally talk me through it".
Every machine equipped with the Bosch IPC and PCL card, however, is equipped with the facility to log into Clifford Engineering's server in Pietermaritzburg and linked up via modem or as an IP has the facility of remote diagnostics and remote support as well as remote software updates.
System architecture
Q: How many I/Os does the installation have? Analog? Digital? Maximum possible?
A: The application has, depending on the machine layout, between 240 to 1000 in and 160 to 540 out. All of them are digital, although the PCL also supports analog. The maximum possible is 80 000 in/80 000 out.
Q: What impressed you most about the architecture? Open standards, wide range of drivers, the ability to upgrade, etc? Please elaborate.
A: The IPC2 with its PCL card is compact and high-tech and at the same time very cost-effective. It operates like a normal PC just more powerful and it is easy for me to use. I did not have to go on any course to learn how to use it. I just learnt by trial and error and in a very short time had a complete understanding of the system and software. It has an open structure and it is easily integrated with other Windows applications.
Q: Does the PLC have a built-in user interface? Describe.
A: Yes. The PCL has a touchscreen interface that operates in a Windows NT environment.
Q: What sort of redundancy is built into the system?
A: The redundancy in the system is sufficient to shut down properly in abnormal circumstances.
Compatibility
Q: Do you run the PLC in conjunction with any third-party application software or hardware? Describe.
A: In terms of software, WinDP and WinSPS are software packages to configure and program the PCL, in this specific environment it runs in conjunction with a VB6 MMI application as well as Excel as a database. The PCL card is run as a realtime system (VX-Works) using the resources of the IPC and allowing certain time slots for the Windows applications. Any additional hardware required are remote /distributed I/Os, which can be Profibus DP; Interbus_S; CANopen or DeviceNet. For this you can use any vendors remote or distributed I/Os that are available for the relevant fieldbus system.
Conclusion
Q: What impressed you the most about the system?
A: The versatility of the PCL to allow you to do anything you want, from a simple logic control to a complex mathematical or robotic control, like the one we used it in. The problem with many of the other PLC systems is that when you want to expand your system to include robotics, you have to get a special interface card for robotic control. The Bosch PCL allows you to constantly upgrade and expand your application, without changing the hardware or software.
Q: What was the predominant feature (or features) that made you decide to employ this PLC, rather than another (ie ease of use, support from the vendor, upgrade path, redundancy features etc)?
A: Its dynamic flexibility, as well as its unlimited ability to expand in size and functionality. It is a high-tech and professional system at a good price.
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