Automation And Controls5 10

Automation and Controls

Tamper Resistant Little Tikes Key Lock ABC Shielded Harley Davidson
Top Sealer Auto Positioner Auto-Assembly Glovebox Radioactive Robotic Crating
Applicator Isotope Closing Station System

3600 Rider Trail South A Top 50 Company phone:314.785.0900
St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044

Specific Automation Capabilities
Automation Hardware Platforms HMI Systems
Labview, Wonderware and
• PLC – Rockwell Automation, GE
Intellution
Fanuc and Modico
• PC Based - National Instruments
• DCS Platforms – Info-90 and
Emerson Delta-V
• Vision Systems – National
Instruments and Cognex
• Robotic Systems
• Communication Protocols – CAN
Bus, Mod Bus, Ethernet/IP, RS -232,
RS-485

Process and Discrete Automation Capabilities
• Automated Weld Systems
• Punch and Drill Equipment
• Temperature, Flow, and PH Control
Systems
• Vibration, Optical, etc.
• Data Acquisition Systems
• Alternative Energy Systems
• Packaging Systems
• Quality and End of Line Tester Systems


Honeywell
GTA Welder Control System Upgrade
• Honeywell Federal Manufacturing and Technologies LLC
utilize high-precision welders for the U.S. Department of
Energy

• Honeywell wanted an upgrade to be developed with
Commercial Off-The-Shelf (COTS) hardware and open-
source software so it could be easily supported and
expanded in the future without having to be completely
redesigned

• Innoventor’s solution provides a Host PC (Windows
XP) with a touch-panel computer (Windows CE) for
user interfaces

• All of the software was written using LabVIEW

Honeywell
Federal Manufacturing and Technologies
EB Welder Programming and Hardware Updates
• The Customer asked Innoventor to create a new
control system for their high precision electron beam
welder
• The new system needed to meet very tight timing
requirements and maintain/improve the system
safety features
• The Team used National Instruments hardware and
LabVIEW software to create the new control system
“The project… exceeded our expectations with
respect to performance and ease of
• Innoventor also updated the user interface to use…(Innoventor) came up with innovative
provide process improvements and reduce solutions to numerous challenges
throughout…”
operator input errors Letter of Commendation from Honeywell’s Principle
Weld Engineer

Bausch and Lomb
Surgical System Testing and Validation Software
• Bausch & Lomb, a major manufacturer of eye health and ophthalmic surgical
products sought Innoventor’s expertise in developing test software for a new
anterior eye surgery system
• The system includes six to 12 modules (including a controller PC), each with
different functionality, all communicating with one another via a CAN
communications network
• Innoventor utilized the great synergy of NI’s
LabVIEW and TestStand packages, developed a
robust software architecture with rich features
bringing great value by delivering a suite of inter-
connected software packages that served
different needs but re-used much of the same
code

Mold Drawer Automation
Major Heavy-equipment Manufacturer
• Innoventor developed an automated system for moving
mold sections into and out of molding presses
• Fourteen presses run a total of 100 different molds; each
mold containing several different sections, or drawers
• The system uses hydraulic cylinders with
electromagnetic end affecters to allow the operator to
move the drawers into the press, as well as, remove the
drawers at the push of a button
• The hydraulic cylinders are vertically adjustable and
designed to accommodate more than 100 different molds
• The system uses electromagnets to attach all of the
different drawer types, minimizing the modifications made
to the mold drawers

BD Diagnostics - Accu-Glass
Automated Parts Handling System
• Innoventor developed an automated handling system for a cleaning process
using hydrofluoric acid, a substance that is very hazardous to human health
• The previous cleaning process required the manual placement of material into a
bath of hydrofluoric acid and a health risk

• The new system:
- Consists of a 2-axis configuration that
moves the basket in and out of the
hydrofluoric baths and rinse tank
-Required the chemical compatibility of
the materials used in the handling
system
-Used PVDF(Kynarr) plastic for the gripper
due to its excellent chemical resistance to
hydrofluoric acid as well as its
dimensional stability and mechanical
strength

Comtrak Technologies, LLC
Redesign of Digital Video Recorder Update
VCU Enclosures
• Innoventor developed a solution for the complete redesign of an existing Digital Video
Recorder and an upgrade series of enclosures and packaging for a new line of digital video
recorders for use in the surveillance and security industry
• The box design had to maintain certain existing components and commonality while allowing
for the use of “Hot Swap” hard drives that could be used in 2 different style of boxes
(A 4 channel unit and a 16 channel unit)
• The outer enclosures and internal structures were designed and packaged to securely
house all components and allow adequate access for service while minimizing production
costs
• Numerous tang-in-slot type self location/fixturing features were
incorporated to allow for reduced down time and simplified
assembly and maintenance


Vision Hardware Equipment Interface
Dell laptop for
file storage and Trigger input
parameter
adjust
ET Hub

Iomega
camera
RS-232 interface

Robot Controller

Robot shown as example only.

LCD Monitor
displaying real IR Camera
National Instruments
time image and
CVS-145x
results
This document is the property of Innoventor, Inc. It may not be
reproduced without Innoventor, Inc. written permission or used for other
than Innoventor, Inc. authorized purposes.


Chemical High Speed Processing Equipment
• Bag Fill Line design met a
critical and highly defined
pharmaceutical requirement
for sterile processing of a
blood based product

• A PLC controls two of the
Sigma Chemical Lines –
Clean in Place and Product
Mode Sigma Chemical Bag
Sigma Chemical Bag Serum Fill Line
Serum Fill Line


Harley-Davidson Robot
• The Robotic Crating
System is an automated
recyclable crating system
that allows for repeated
use of motorcycle
packaging
• Innoventor project
managed the build of this
automated system on
site Harley-Davidson Robotic Crating System


First Tier Automotive Supplier
Key and Lock Line
• Innoventor is the first outside source to
build a machine for this first tier
automotive industry supplier
• Reverse engineered this system from
hundreds of photos and measurements
of an existing line in the plant
• The line assembles and checks
complete key/lock sets
• Automated line has 12 stations, 6 with
Allen Bradley PLCs and a final 100%
check GE Fanuc Robot

ABC Labs Automated Processing Equipment
• The automation enclosed in the
Glovebox drastically reduces
manual operations used in
processing a specific highly
sensitive pharmaceutical
product
• PLC controls used for the
automated glovebox are
concept software and Modicon
ABC Labs Automated Glovebox
PLCs

Republic of Tea
High Speed Tea Bagger Equipment
• Innoventor designed and built this
automated process to sort and pack
round tea bags into canisters
• Allen Bradley PLCs
• 2000 bags per minute(500 per lane)


Little Tikes
Automated Welding Equipment
Little Tikes Automated Positioning
and
Robotic Welding Systems

Automated Commercial Play System


Plant Automation

High Production CNC Controlled Machines

A PLC controls this Motor End shield drill, ream and bearing
press for a fractional horsepower electric motor manufacturer

Republic of Tea Top Seal Applicator
• Optimized the software &
pneumatics to increase the
response time
• 3 cameras used to first find a
barcode and then second to give
the location of the edge of the
barcode
• The seal applicator was able to
calculate the amount of rotation
to orient the can for top seal
application


Husky Corporation Laser Marking System
• Laser technology designed to burn serial
number and product information onto gas
nozzle connections
• Designed for easy operator interface with
a high level of dependability and safety
• Significantly increased the customers
production over the manual hand
stamping previously employed


B-D Vision Systems
Vision Inspection Systems
• Allen Bradley PanelView touch screen operator interface
• Precision Haas rotary index table, accurate placement
to ± 15 arc-sec
• Allen Bradley SLC 5/03 controller

Becton Dickinson Accu-Glass Rotary Index Vision Inspection Machine


Nascote Automated Production Equipment

• Automated equipment that
applies information labels to
the curved grill surface of
Ford SUVs

• Allen Bradley PLC Controls

Nascote Industries Label Applicator


Overview of
LabVIEW Projects
Innoventor, Inc.

Glucose Meter
Tamper Resistant Probe Hardware Navy FLIR
Circuit Breaker
Top Sealer Applicator Simulator Optical Alignment Tool
Slake Tester Testing

A Quick Word About Innoventor
Got problems?
We have solutions!
• Full service integrator
specializing in NI tools and
hardware
• NI certified developers and
architect
• Certified Alliance Member since
1994
• Innoventor engineering team


NI Expertise
• LabVIEW
– Many programming projects and turn-key systems
successfully delivered
– Specialty areas including Real Time, Vision,
Motion, Control, Simulation, Data Presentation,
Connectivity, etc.
• NI hardware platforms: PC, PXI, FieldPoint,
cFieldPoint, SCXI, Compact Vision, etc.


Top Sealer Application
• Apply a top seal with wings to a can
– Top seal safety assurance
– Can 2” diameter by 6” tall
• In feeding and out feeding of cans
• Sort cans with different labels, up to 5 types, after top seal
application
• Many different label types that represent can contents
– No restriction on graphics
– Only the bar code is present on every label


Machine Overview
Operator screen

Sorting tables

In-feed conveyor

Panel with PAC

Power condition
and motor
drives


Hardware Diagram


Slake Tester
• Production and quality
control test system
– LabVIEW executable
– USB data acquisition device
(USB-9211)
• Automate procedure of
testing reactivity per ANSI
standard
– Elimination of errors in data
recording
– Logging of results
– Minimize operator training

Slake Tester Interface


Circuit Breaker Production Life Testing
• PXI based and distributed
• High speed synchronous
sampling on multiple channels
• Matrix switching used to
multiplex inputs from test cells
• Synchronized triggering form Ia
master controller Ib
Ic
• Separate PXI system used to Va Vb Vc
simulate master controller and 3Phase Breaker
test data Load Bank


Data ACQ Hardware Overview
• Analog input (NI PXI-6115 Qty 3)
– 12 bit, 10MS/s each channel
– 4 channel, simultaneously sampling
– 500 kHz/50 kHz 3 pole Chebyshev filter software selectable on channel basis

• Matrix switch (NI PXI-2503 Qty 2)
– Used to route individual breaker voltage and current sensors to analog sampling inputs
– 4 x 6, 2 wire (provides signal pairs for noise immunity)

• Digital I/O (NI PXI-6527)
– 24 inputs
– 24 outputs
– 0 to 30 volt


Navy FLIR Optical Alignment
Tool Improvement
• LabVIEW program to monitor real time measurements and log stability tests
• Electronic 2-axis autocollimator read using DAQ in PXI chassis
• Thermocouples monitoring gradients read using FieldPoint modules

Measurements Modeling and Design
Test Set Up

Test 2 Data

90

70
Alignment (arc-sec)

50
Xpos(arc-sec)
30 Ypos(arc-sec)

10

-10 19 21 23 25 27 29

-30
Temp (deg C)


Test and Measurement
New Product Development
• Kinetic hammer with auto feeding nail strip for use on products
such as house wrap and roof felt
• Accelerometer measurements used to “see inside” and time
interactions

Accelerometer

Horizontal Orientation
100

Response 80

60

40

during 20
accel

0 accel
0.6 0.65 0.7 0.75 0.8
-20

hammer impact -40

-60

-80

-100
time(sec)


Automation, Inspection, and Test Systems
• National Instruments LabVIEW and
numerous hardware platforms
• Unique vision inspection methods
• Systems for process control and Test 2 Data

product evaluation
90

70

Alignment (arc-sec)
50
Xpos(arc-sec)
30 Ypos(arc-sec)

10

-10 19 21 23 25 27 29

-30
Temp (deg C)


High Resolution Optical Inspection
• Glass rod (1mm diameter x 10mm length) with small center channel for flow control
in medical product
• Application created in Vision Builder and LabVIEW to screen for “extra” channels
• Clear glass and small features present unique imaging challenges
• Illumination source created to make the channels light up in the image
• System was tested for gauge read and repeatability and surpassed requirements
significantly


Glucose Meter Probe Hardware Simulator


Using FieldPoint and LabVIEW Application
for Production Unit Verifications


Test/Certification System
for Enteral Feeding Pumps


Nano-particle R/D Reactor Controller
• Very dynamic control and data
collection system used for a chemical
reactor in development of nano-
particles
• User can assign up to 48 independent
PID thermal control loops without
modifying the program
• Data I/O can be remapped by user
without changing code
• Tags are assignable to view groups
for quick access to similar parameters
• Also includes monitoring and
command of motors, mass flow
meters, pressure sensors, etc.


Liquid Chemical Pilot Plant R/D
• Control and data collection system for
research and development of a liquid
chemical production
• Wide range of interfacing
– Multiple RS-232
– ModBus
– 4-20 mA
– Discrete I/O
– Analog volts
• Shutdown control and monitoring
implemented from program
• System has made many day runs
without incident


Automated Wheel Audit Test Station
• Rack mounted PC based system with
DAQ and Motion
• Application written entirely with
LabVIEW development system
• Fully automated measurement and
analysis of wheels
– Four attributes of run out
– Selectable speed of operation
– Synchronized LVDT sampling with angle
– Exact repositioning for marking
– Plots comparing to 1st harmonic and
calculation of 20 harmonic terms
• Precise to within 0.001 inches


Development of Genset for Alternative Power
• Application written entirely with
LabVIEW development system and
includes remote monitoring with
DataSocket
• Broad range of interface hardware
– SCXI (TCs, Pressure, Flow,
Power)
– SCXI relay for load bank control
– DAQ for fast cylinder pressure
– RS-232 for emissions gas analyzer
– CAN for generator control/monitor
and for engine control/monitor
– RS-485 for power meter
communications


Portable Oxygen Unit Production Test System
Print
• Production test system is part er
RS-
of the final test of a medical Comput
232
Unit Under
Test Flow
product which dispenses er Pressu
re
meter

oxygen on demand to conserve DAQ card SCB-
68
Flow

Breathin
the supply Analog
signals
g
simulato

• Original testing done using a r

manual approach and required
3 people on 2 shifts (6 total) to
maintain production rates
• Test system reduced
manpower to 1 person on 1
shift and still has excess
capacity for production rate
increases

Innoventor, Inc.
A Solutions Engineering House

3600 Rider Trail South
St. Louis MO 63045 (USA)
P 314.785.0900
F 314.785.0044
www.innoventor.net


Automation And Controls5 10

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