Automation manufacturers such as Abco Automation are using programmable automation controllers (PACs) from National Instruments to seamlessly integrate testing and automation solutions into existing PLCs. Using the NI LabVIEW graphical development environment running on an embedded PXI controller, Abco created a PAC solution for its automotive wheel speed sensor assemblies and integrated the solution with existing Allen-Bradley PLCs via an RSLinx OPC server for increased throughput of one part every six seconds.
In the current competitive business climate, engineers and manufacturers face productivity demands that drive the need for more automation throughout the manufacturing process. As a result, many companies are augmenting traditional PLC-based assembly lines with more cost-effective, PC-based technologies. The speed, accuracy and industrial communication capabilities made the NI PAC platform the ideal solution for ABCO to meet rigorous application requirements, including interoperability with existing factory control systems.
"National Instruments OPC capabilities and interoperability with PLCs were key factors in the success of this project. The ease with which NI PAC hardware can speak to the Allen-Bradley hardware saved me valuable programming and integration time," said Arif Bustani, Abco electrical engineer for the project.
Abco used an NI PXI-1042 chassis and an NI PXI-8186 controller along with several NI PXI-6070E data acquisition (DAQ) devices to develop a high-speed assembly line that acquires and analyses waveform data and then communicates with the existing PLC-based control system. Using NI LabVIEW DataSocket technology and RSLinx from Allen-Bradley, ABCO integrated the NI PAC hardware with traditional PLCs for seamless control and data monitoring. The PAC system acquires waveforms from an encoder connected to a tone wheel operating at a specific RPM and analyses the data to determine pass and fail grades. Acceptable parts are sent to packaging while rejected parts are isolated.
"The automotive sensor test solution from ABCO is an example of how traditional PLC-based automation can be combined with powerful, cost-effective PC-based automation using PACs and the open, single development environment of NI LabVIEW," said Robert Jackson, NI PXI product manager. "The NI PAC industrial platform combines the best features of the PC - such as flexibility, processing power and customisable software - with the reliability and ruggedness of the PLC."
For more information contact NI South Africa, 0800 203 199.
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