Is There An Effective Way To Control The Textile Production Machines We Manufacture That Also Captures Important Data So Our Customers Can Use It To Improve Their Processes?
What Our Client Said
We are a large textile machinery OEM (original equipment manufacturer), and the last to be based in the United States. We create world-class machines that produce a large amount of the world’s denim supply. Our goal is to provide our clients with the most efficient and user-friendly machines possible. In order for this to happen, we need to incorporate new features that increase the availability of user data and simplify the process of on-site programming and commissioning.
What We Heard
Our textile machines are installed in many different manufacturing facilities around the world. With this distance factor in mind, we need a systems integrator with the resources to incorporate state-of-the-art control systems with our machines in order to provide end users with optimal control and data analysis capabilities. As an OEM, the new system must also give us the ability to easily troubleshoot and commission each machine.
What We Did
Versatile controls for OEM machines, integrated historian, data reporting • Data analysis helps end users improve productivity • Simplified installation and commissioning
LSI’s team started by listening to the customer’s extensive background information on this unique challenge. This knowledge gave engineers a clear picture of the strengths and weaknesses of the existing PLC and HMI systems, as well as clues about how to improve overall performance. Based on past experience, LSI determined that a combination of Inductive Automation’s Ignition platform and Allen Bradley PLCs would be the best solution to meet – and exceed – the customer’s requirements. Not only would the system provide a wide range of powerful historian and reporting capabilities, it would be versatile enough to be installed on almost any type of hardware or operating system. Thanks to our deep understanding of the Ignition platform, LSI’s Data Intelligence team was able to successfully integrate the new state-of-the-art control system without hindering production. We were also able to optimize the existing PLC code to allow for rapid setup and to minimize programming time for the customer.
- Systems integration
- Data historian
- Ignition system programming
- PLC code optimization
- CAD model configuration
- Hardware sizing and specification
The Results Speak For Themselves
Easier troubleshooting and commissioning for the OEM
LSI developed a versatile control solution that gave the OEM the ability to more easily install and commission their world-class textile manufacturing equipment. The system’s remote viewing capabilities also allow the OEM’s support team to troubleshoot whenever necessary.
Improved control and data collection for the end user
By implementing the Ignition platform, LSI simplified and maximized process control and data analysis for the end user. Powerful data collection capabilities and historian functionality provide important information to the end user (including reports on productivity, downtime, resource usage and many other associated processes), allowing them to make better production decisions. The system also allows for the integration of outside ERPs and reporting systems.
Simplified touch screen control
The customer required a system that would provide easy data access without relying on any specific HMI. They also wanted to use a PC and industrial touch screen to control the process. Leveraging the Ignition platform, LSI provided the client with an admin screen capable of easily customizing drive settings, alarm parameters, PID loops and new transmitters for each section of the production line.
The fact that each machine’s end user would have its own budget and unique set of requirements made it imperative to develop a control system that provided customizable options. LSI’s solution allowed the customer to easily customize hardware and software licensing costs based on the requirements of the end user. Additionally, if the end user chose to purchase several textile machines, multiple HMI projects could be run from one server without any additional licensing fees.
LSI Listened, then we put our knowledge and experience to work, utilizing the best combination of technologies to successfully integrate a state-of-the-art control system that would not only meet customer expectations, but exceed them. By choosing to use Ignition (from Inductive Automation), LSI equipped the customer’s state-of-the-art textile machines with the capabilities to maximize process control and simplify data analysis. This benefited both the OEM and the end users of the machines.
LSI’s team worked hard to fully understand the OEM’s unique challenges and implemented a solution for each of them. The resulting textile manufacturing equipment includes an optimal combination of intuitive control, powerful data analysis and crucial process visualization.