PROBLEM:  Client needs to integrate and synchronize equipment supplied by a variety of foreign and domestic vendors into a single handling, preparation and painting line. The overall line length is five hundred feet with nineteen different conveyor systems. The equipment included boilers, chemical tanks, spray washer / applicator, loaders, unloaders, gas fired ovens, dryers, infrared, paint applicators, ventilation, and conveyors.

SOLUTION: Provide P&ID diagram based documentation for the overall system. Assemble an instrument / equipment database that all vendors can access and contribute to. All parts are tagged with the P&ID assignments prior to shipping to the site. The end result of the P&ID documents, combined with the related database are that all equipment is on-site or accounted for when assembly commenced. The P&ID's become the guiding document that all the trades follow. 

Specify that all conveyorized equipment include "C" face motors and self-aligning ring style encoders. The motors and encoders are connected to motor ratio controllers and variable frequency drives. This system permits equipment with different maximum speeds and differing conveyor systems to transport individual sheet steel in a uniform manner. Gaps between sheets are held to two inches minimum to minimize paint and chemical waste.

The control engine for this project is multiple Allen Bradley PLC560's and SLC 5/04's on a data highway plus network. The PLC560's also communicate with the motor ratio controllers to permit trimming conveyor follow ratios to suit different products.

Multiple Intouch Wonderware terminals are connected to the DH+ network to provide operator interface. Interface at the automated Load and Unload equipment is through AB Panelview 550's.

BENEFITS:  Installation goes smoothly with minimal supervision. The end result of this automation projects was a reduction in manufacturing labor from 100 individuals to five. Production  hours were reduced from two shifts to one. Two patents were issued for the conveyor synchronization system and overall line control scheme.