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The project was necessary to streamline the process of tracking raw material usage, ensuring precise record-keeping for material consumption.

Without an automated system, manual tracking could lead to errors, inefficiency, and lack of oversight in recipe compliance.

A solution was needed to monitor real-time consumption, alert operators to incorrect usage, and maintain audit trails for recipe modifications.

• The software reads consumption data directly from the HMI and logs material usage in kilograms.
• It features customizable reporting tools, allowing users to generate reports based on their specific needs.
• The system also automates the generation of consumption reports and sends them via email.
• Additionally, it includes an alarm system to notify operators if the wrong percentages of materials are used based on the defined recipe, and it provides audit information whenever a recipe is modified.

The company faces a challenge due to the lack of an energy monitoring system, resulting in no power consumption records for the plant.

Additionally, there’s no tracking of load and power consumption by department, preventing the efficient distribution of load as per requirements.

• An EMS SCADA System integrates real-time monitoring of power grid operations. It combines Energy Management Systems (EMS) with SCADA to provide utilities with tools to supervise, analyze, and optimize electrical networks.
• The system collects data from various Energy Meter, enabling operators to monitor voltage levels, frequencies, and power flows. EMS SCADA supports critical functions such as load balancing, fault detection, and energy forecasting, ensuring reliable and efficient power distribution across the plant.
• The system automatically generates hourly, daily, and monthly energy consumption reports. Users can also manually download reports as needed to meet their specific requirements.

Data Recoding & Product tracebillityg

Our project revolutionizes testing by consolidating HI-Power testing and three other crucial tests into a unified SCADA system.

This innovative solution ensures continuous data logging, automatically rejecting drivers that fail any test.

The system’s dynamic dashboard provides real-time insights, while a robust report generation feature allows in-depth analysis. This comprehensive approach enhances efficiency and accuracy in testing processes.

The integration of these functionalities empowers the project to streamline operations, ensuring not only rejection of faulty drivers but also providing a detailed overview through data visualization and reports.

This project marks a significant advancement in testing technology, offering a holistic solution for seamless and effective testing procedures.

• The system facilitates the generation of testing and packing detail reports for comprehensive documentation.
• Rejecting failed drivers before packing ensures a higher product quality in the market, enhancing overall product integrity.
• A user-friendly interface for an efficient operational experience.

Upgrading Ficep CNC Machine

APS faces a unique retrofitting challenge in modernizing a machine manufactured by a global industry leader while preserving its existing user interface and operating method. The task involves replacing the conventional CNC control system with a state-of-the-art motion controller, ensuring compatibility with contemporary manufacturing standards without disrupting familiar operational procedures.

The challenge lies in seamlessly integrating the new technology while retaining the user interface and operating methods that operators are accustomed to. The goal is not only to enhance the machine’s performance and efficiency through cutting-edge technology but also to preserve the established efficiency and familiarity that come with the legacy interface.

• In their quest to modernize the machine, APS sought the following key features and critical attributes.
• Elevating the servo drive and motor by transitioning to the Kollmorgen AKD series drive and AKM series motor.
• Maintaining continuity with the same operating method for operator familiarity.
• Adapting machine wiring to suit the environment seamlessly.
• Enhancing performance and precision for optimal machine functionality.

Manual potting conveyors for asphalt potting in lighting driver covers present safety challenges. The manual process involves direct human interaction with hot asphalt, posing burn risks. Accidents may occur due to handling errors or exposure to high temperatures. Additionally, manual operations can result in inconsistent potting material application, affecting product quality. To address these challenges, automated solutions with safety features, like PLC and HMI systems, are recommended. Automated potting conveyors enhance precision, reduce accidents, and ensure uniform encapsulation, contributing to a safer and more efficient manufacturing process for lighting driver covers and enclosed applications.

The Potting Conveyor for LED driver machines offers a comprehensive solution with an Auto Conveyor system driven by PLC and HMI, featuring a servo system. This innovative design allows seamless handling of multiple types of LED drivers with efficient hot asphalt potting. The integration ensures time efficiency, maintaining high-quality standards, and promoting safety. The precise control guarantees accurate results, and the recipe storage in the HMI facilitates easy access to different configurations. Altogether, this automated solution optimizes production processes, minimizes errors, and enhances overall efficiency in the potting of LED drivers.