Devro Teepak

SoftPLC was used with the company’s previous controller to eliminate timing issues, increase computing power, reduced cost, and improved reliability.

Engineers frequently encounter difficulty in control applications when multiple tasks need to occur in a coordinated manner. A food processing OEM found this to be the case in one of their machines. In the past, the OEM used an SLC-500 PLC for machine control, in conjunction with a Basic module which communicated to a high speed Servo via an RS-232 channel. Timing problems resulted because: (a) the data coming into the Basic module was limited to 19.2Kbaud, (b) the Basic program needed to run a large number of calculations for the Servo before it passed the information to the PLC, and then (c) based on where the PLC was in its cycle, the control did or did not happen in the proper sequence or fast enough.

The solution chosen by the OEM was to use SoftPLC, a PC based open architecture control system that runs “PLC-5 like” ladder. The servo calculations required were extremely lengthy and needed to be done within 1/100 second, so rather than burden the control PC with this, they were still done in a separate PC in Basic. The hardware selected was a Ziatech STD-32 multi-processor system–1 CPU running SoftPLC for control, 1 CPU performing the calculations, and a third CPU running an operator interface program and the SoftPLC ladder programming software, TOPDOC. High-speed APIX I/O was selected, which fits right in the Ziatech backplane. In a global memory area, information is passed between the SoftPLC and the Basic program.

The OEM was able to convert the usable SLC-500 logic to run in SoftPLC, and wrote a C function to read/write to the global memory area – all in less than one day! All objectives for the machine re-design were reached, including inter-communications between the various control elements, cost of machine, processing speed and reliability of operation.

This application success story is from SoftPLC
Tri-Phase Automation is a SoftPLC distributor in Wisconsin.
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SoftPLC Produces a BioMass of Power

SoftPLC handles biomass electric power plant

In Northern California, SoftPLC controllers, Tealware I/O and Web Studio are used by Blue Lake Power in their biomass electric power plant. The plant was originally a coal-fired plant that has been converted to burn woody waste. It uses wood chips as its mains fuel source for a conventional boiler which powers a steam-turbine generator.

Four SoftPLC’s are used for material handling, for both the input fuel and the ash by-product conveyors, and for all of the process control. Hardbook CPU’s with remote Tealware I/O connected via Ethernet are used for all the systems. Web Studio is used for the plant SCADA system which includes a redundant server, several desktop client stations and two large LCD displays in the control room. Web Studio is also used as the HMI running on portable tablet PC’s by the maintenance crew.

The Blue Lake plant adds over 93,000 MWh of renewable power to California’s grid and provides significant economic and environmental benefits for the city of Blue Lake and the state of California. The plant’s fuel procurement plan improves forest health, reduces hazardous fuels, and provides stability to the woods industry and local communities.

This application success story is from SoftPLC
Tri-Phase Automation is a SoftPLC distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Aggregate Plant Automation

SoftPLC provides major benefits to aggregate plant automation

At the StoneCo Newport Facility, Etheridge Automation installed controls for the Primary and Secondary crushing plants to control all operating equipment and the plant feed. In the Primary plant, the SoftPLC control system increased the production capacity by 20%, allowing the plant to cut the operating time from 10 hours per day to 8 hours. Additionally, major downtime events were greatly reduced, increasing the plant availability.

This application success story is from SoftPLC

Tri-Phase Automation is a SoftPLC distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Overview of PLC-SCADA-PC/104 Control System

Remotely operated vehicles get help from SoftPLC

Challenge
The control system outlined here concerns an underwater remotely operated vehicle (ROV). The offshore Oil and Gas industry has become increasingly dependent on ROVs as the global trend in deep water sea bed installations increases. The system comprises of three control units.

Application Solution
The PLC units are dedicated to updating local data input and transferring this to the remote unit where it is regarded as data to be output. Thus, at any instant, each controller has global data that ‘mirrors’ the last state of the controllers’ I/O. The PLCs are comprised of embedded-PC and I/O modules using the industrial computer PC/104 format and ISA bus standard. The identical surface and subsea controller 80486 DX2/66 processors run a 32bit real- time, multitasking kernel operating system SoftPLC. This operating system, once loaded into RAM, has complete control of the CPU at all times.

Benefit
Redundant path switching for the communications loops to the PLC has been incorporated so, if the primary data path fails, a back up fibre or copper pair can be used to communicate with the other control unit.

This application success story is from SoftPLC

Tri-Phase Automation is a SoftPLC distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Weyerhaeuser wood grading system

In order to eliminate the bottleneck at their wood grading system, Weyerhaeuser turned to a local systems integrator who developed an open architecture control system utilizing a SoftPLC in Tealware™ PLC, coupled with RSVIEW32 as the operator interface. SoftPLC in Tealware I/O are used for control of the majority of discrete field devices, as well as a DeviceNet network. SoftPLC In Tealware I/O are used for control of the majority of discrete field devices.

Improving the capacity through the lumber grading station was the most logical way to increase overall productivity and profitability of the entire system.Weyerhaeuser turned to a local systems integrator to recommend control and data acquisition products, as well as an overall system approach to improve the grading station. Given the needs and goals of the Weyerhaeuser system, the integrator designed and implemented an open architecture control system utilizing a SoftPLC in Tealware™ PLC, coupled with RSVIEW32 as the operator interface.

Overall, by combining products from multiple vendors — SoftPLC In Tealware CPU and I/O, DeviceNet I/O, a web browser, and RSVIEW32 –Weyerhaeuser has been given the stability of a traditional grading control system while providing immediate improvements and a platform on which to build in the future. Most importantly, the company effectively doubled the throughput of the grading station, the original goal of the project.

This application success story is from SoftPLC

Tri-Phase Automation is a SoftPLC distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

US Army Corps of Engineers – Hydroelectric Design Center

SoftPLC selected as Unit Controller Standard for large Hydro-Electric Power Plants

The USACE-HDC conducted extensive product reviews followed by a lengthy product testing process. All major proprietary hardware PLC’s and open architecture PC based control products were reviewed and tested. Due to the mission critical nature of the application, the process also included stress testing to determine the robustness and reliability of each product.

SoftPLC was ultimately selected over all other alternatives because it offered a flexible, open architecture system for applications today and into the future. Additionally, SoftPLC was also most suited for the mission critical nature of turbine generator control, proven by the testing to be an extremely reliable product.

The turbine generator control project has proven extremely successful, with the first turbine generator units under SoftPLC control since 1999. This success led to hundreds of other applications for SoftPLC into the hydro plants such as turbine blade control, fish way and screen automation, powerhouse mux control, orifice gate control, annunciators and others.

This application success story is from SoftPLC
Tri-Phase Automation is a SoftPLC distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Sugar Ethanol Plant Controls

Dracena Obra, an ethanol producer in Brazil, selected Mitre Engenharia Ltd. to implement the automation for their entire plant. Since 1998, Mitre has provided open architecture control systems using SoftPLC® Programmable Automation Controllers (PAC), Profibus I/O, and Mitre’s SCADA software called PlantJar.  SoftPLC was chosen as the controller for a number of reasons. SoftPLC is an open architecture PAC that provides capacity, processing power, and flexibility unmatched in other systems – at a much lower price. SoftPLC provides virtually unlimited user application memory, versatile PID control and floating point calculations. Extremely fast update times allow fast response I/O to be handled even with significant calculations being performed.

This application success story is from SoftPLC
Tri-Phase Automation is a SoftPLC distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote