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Testimonials
“Very impressed…kudos to Viewpoint”
I really want to thank you for all your help getting us to this stage in automating our testing. We had our customer in this week to oversee some testing and they were very impressed, which is definitely kudos to Viewpoint.
“Significant value”
The Viewpoint team provides significant value to our projects, and I really enjoy working with Viewpoint.
“Valuable part of our global team”
I have been working with Viewpoint for 15+ years on multiple projects. They have always provided creative and quick solutions to all of the problems we have placed in front of them. I have always considered them a valuable part of our global team.
LabVIEW Case Studies | Projects
LabVIEW-based Data Logger for Product Validation of Commercial Equipment
LabVIEW-based Data Logger for Product Validation of Commercial Equipment
Synchronizing data from multiple data logging instruments
Client – Manufacturer of commercial equipment
Challenge
The client already had a method in place to log data needed for validation testing. However, this data was acquired from multiple independent data logging applications. They needed something to aggregate the data and align/synchronize the data across multiple instruments.
Solution
Viewpoint developed a LabVIEW-based product validation solution that continued to utilize the existing data logging hardware, but uses software to aggregate & synchronize the data from multiple sources. This simplifies post-processing.
Benefits
- Synchronized & aggregated data from multiple instruments
- Ability to add capability for new instruments later on
- Real time graphing of all channels
- Channel averaging across multiple instruments
- Ability to save data acquisition configurations for future use
- Faster channel configuration than current data logging applications
System Overview
The data logging software unifies the collection of data for a particular validation test. The software configures each instrument, kicks them off, logs the data to a TDMS file, and also graphs data and displays real-time values.
| SOFTWARE FUNCTIONS |
|---|
| Instrument configuration |
| GUI |
| Data Acquisition |
| Data Synchronization |
| Data Logging |
| Multi-channel averaging |
| HARDWARE USED |
|---|
| Keysight Data Logger |
| Fluke Data Acquisition DMM |
| INTERFACES / PROTOCOLS |
|---|
| RS-232 |
| USB |
| Ethernet |
Online Monitoring of Industrial Equipment using NI CompactRIO
Online Monitoring of Industrial Equipment using NI CompactRIO
Improving Maintenance of expensive industrial equipment
Client – Large Industrial Equipment Manufacturer
Challenge
The maintenance of the equipment was not always done at the prescribed intervals because the cost of shutting down the plant is significant. This sometimes resulted in an equipment failure. This particular application is for equipment/machinery in the energy/power industry (a generator).
Solution
The online monitoring system monitors a particular parameter of interest to send warnings and alarms to the control room so that the operators know when maintenance needs to be performed on the particular part of interest. This system has been installed in multiple plants.
Benefits
- Enables condition-influenced maintenance intervals vs periodic intervals
- Reduces probability of catastrophic failure by providing warning indicator
System Overview
The system monitors the generator collector health. NI-based data acquisition hardware acquires the signal of interest, logs the raw data, processes the parameter of interest, and triggers/sends warnings and alarms to the control room. LabVIEW FPGA was used for analog and digital IO and a sensor check. LabVIEW Real Time was used for the calculation, data logging, serving data to the HMI and alarm/warning checking.
| SOFTWARE FUNCTIONS |
|---|
| Touchscreen GUI for data/alarm display and system configuration |
| Data logging |
| Signal processing and alarming |
| HARDWARE USED (selected by customer) |
|---|
| NI cRIO |
| NI Touch Panel Computer |
| Multiple NI C Series Modules |
| INTERFACES / PROTOCOLS |
|---|
| TCP/IP |
*- images are representative, not actual
Endurance Testing using NI PXI
Endurance Testing using NI PXI
An automated system permits faster validation, unattended test, an increase in throughput, and can free up resources for other tasks during the weeks long endurance test.
Client – A manufacturer of aircraft components in the mil-aero industry
Challenge
New product development drove the need for a new endurance test system for product validation. The old systems were not designed to test the newly designed part (aircraft actuators), and the company didn’t have the time or resources to reconfigure existing systems to perform the testing required.
Solution
The new PXI-based endurance test system provides automated electromechanical testing, full data recording, report generation and a diagnostic panel for intelligent debug. Viewpoint selected the NI equipment, while the test consoles, and other components were selected and fabricated by the customer.
Benefits
- An automated system permits faster validation, unattended test, an increase in throughput, and can free up resources for other tasks during the weeks long endurance test.
- Full data recording with a data viewer enables post analysis, which provides the ability to review and analyze raw signals captured during execution. Channel examples are actuator LVDT position, load, current, and encoder actuator position.
- Summary report capability allows the customer to document the amount of testing completed against the full endurance test schedules.
- A manual diagnostic operational panel provides the ability to verify particular DUT functionality or components without running an entire schedule.
- Systems can be paused and restarted to allow for “scheduled maintenance” of the DUT such as inspections, lubrication, etc.
System Overview
The PXI-based endurance test system enables data collection, deterministic PID Loop Control, emergency shutdown and a diagnostic panel for manual test and debug operation. The system runs endurance test schedules, that are defined as a recipe for test execution. These schedules, which are customer-defined and DUT-specific, are designed to simulate the actual conditions the DUT would see in real world application as closely as possible. LabVIEW-RT was used for the deterministic looping for Closed Loop Control of Actuator Position and Load Control. LVDT demodulation was performed on a PXI FPGA card programmed with LabVIEW FPGA.
| SOFTWARE FUNCTIONS |
|---|
| GUI |
| Summary Reports |
| Full Data Collection for Real-Time and Post Analysis |
| Deterministic PID Loop Control |
| E-Stop Management |
| Diagnostics Panel for Manual Test and Debug |
| Endurance Test Schedule Execution |
| Hydraulic Control Panel for Source & Load PSI Control |
| HARDWARE USED |
|---|
| PXI |
| Various PXI-based Data Acquisition Cards |
| PXI RT Controller |
| PXI FPGA Card |
| INTERFACES / PROTOCOLS |
|---|
| TCP/IP |
Endurance Tester for Mission-Critical Mechanical Component using NI cRIO
Endurance Tester for Mission-Critical Mechanical Component using NI cRIO
Ability to run tests unattended and overnight reduces operator labor and compresses test schedules
Client – Major Aerospace Component Supplier / Manufacturer
Challenge
The client had an older VB & PLC-based test system in place already, but it was obsolete. A new endurance test system needed to be developed to validate prototyped components (in this case, aircraft & aerospace bearings). Many of the prototypes are one-off, so it was important that the test system not destroy the component.
Solution
A new endurance test system was developed to validate prototyped components. The test system can be configured for automatic shutdowns so as not to destroy the component under test in the event of unexpected performance of electro-mechanical subsystem components. The updated endurance tester supports product validation by allowing the product to run under various test conditions (e.g. speed, load, oil flow, temperature) and collecting data for analysis.
Viewpoint developed the software and selected the NI hardware (other hardware was selected by the client).
Benefits
Ability to run tests unattended and overnight eases operator labor and compresses test schedules
Data collection allows for offline engineering analysis
Automatic shutdowns reduce destruction of the prototype component under test
System Overview
The updated cRIO-based endurance tester incorporates configurable profiles, data logging, and automatic shutdown to allow for safer extended validation testing. LabVIEW FPGA and LabVIEW RT were used together to interface with the test hardware sensors and controls. LabVIEW as used create the HMI for the test system.
| SOFTWARE FUNCTIONS |
|---|
| Closed loop control of bearing test oil flow |
| Axial load control |
| Driver for Emerson VFD |
| E-Stop and safety management (shutdowns based on alarm limits) |
| Data collection – temperature, pressure, flow, vibration, frequency |
| Operator/Diagnostic GUI for control of system |
| HARDWARE USED |
|---|
| NI CompactRIO (cRIO) |
| NI C Series Current Input Module |
| NI C Series Voltage Input Module |
| NI C Series Temperature Input Module |
| NI C Series Current Output Module |
| NI C Series Analog Input Module |
| NI C Series Sound and Vibration Input Module |
| NI C Series Digital Module |
| Emerson VFD (Variable Frequency Drive) |
| INTERFACES / PROTOCOLS |
|---|
| TCP/IP |
| TCP Modbus |
Industrial Automation – Improving Manufacturing Process with a semi-automated welder
Industrial Automation – Improving Manufacturing Process with a semi-automated welder
Automating a battery welder to improve consistency and increase throughput
Client
Industrial manufacturer of battery stacks
Challenge
The previous welding method was all manual, prone to errors and inconsistency. The old system also required the operator be in contact with the module while welding without any safety shielding.
Solution
The welder semi-automates the ultrasonic welding of terminals on a battery module as part of the manufacturing process. It allows for welds to be conducted in the same place for every module, reducing variability and operator errors. This system is also quicker than doing the welds manually.
Benefits
- Increased weld consistency
- Improved operator safety
- Increased welder throughput
System Overview
The system semi-automates the ultrasonic welding of terminals on a battery module. The system consists of an ultrasonic welder, XYZ table, and safety interlocks. The table moves the battery module to the correct welding position. Once in position, the Z portion of the table lowers the welder to the correct welding height. The application sends the signal to the welder to conduct the weld. Weld data is saved to a file from the welder Ethernet interface for later analysis. Viewpoint provided the software for this system, while the client provided the hardware for us to interface with.
Considerable attention was paid to addressing faults in the production process to avoid damage to the operator and the battery module during the welding process, due to the high current output available from the battery module.
| SOFTWARE FUNCTIONS |
|---|
| Welding routing configuration |
| Operator GUI |
| Maintenance mode |
| Interface to welder |
| Interface to table & controller |
| Interface to E-Stop & interlocks |
| INTERFACES / PROTOCOLS |
|---|
| RS-485 |
| Ethernet |
| 24V Digital IO |
Endurance Tester using NI cRIO
Endurance Tester using NI cRIO
Multiple International Deployments Helps Prove Product Meets Spec.
Each endurance test can run upwards of 6 months.
Client: Major Automotive Component Supplier
Challenge
A new endurance test system was developed to give more precision in the control setpoint. This additional precision enabled potential clients to review the product performance in real-life situations. Each endurance test can run upwards of 6 months.
Solution
The updated endurance tester supports product validation by providing the desired parameter control method, allowing the client to prove more obviously that their part met the stated specification.
Viewpoint developed the software and selected the NI hardware for the first unit. The client is now deploying copies of this system to multiple international manufacturing plants.
Benefits
- Able to prove meeting a particular product specification of interest
- Closed loop parameter control
- Data collection
- Configurable Alarms
- Emergency shutdown functionality
System Overview
The cRIO-based endurance tester provides closed loop control, data collection, and alarming with controlled and emergency shutdown functions. The operator can manually configure a test or load a saved configuration. After a manual operator check to make sure the setup is operating correctly, a successful test will run its full duration and stop on its own.
| SOFTWARE FUNCTIONS |
|---|
| Touch PC interface / GUI |
| Closed loop parameter control |
| Data collection |
| Controlled & emergency shutdown |
| Alarming |
| HARDWARE USED |
|---|
| NI CompactRIO |
| NI analog input cSeries module |
| NI analog output cSeries module |
| NI digital input cSeries module |
| NI digital output cSeries module |
| INTERFACES / PROTOCOLS |
|---|
| TCP |
Product Validation using LabVIEW RT & LabVIEW FPGA – Electromechanical Actuator Test Stand
Product Validation using LabVIEW RT & LabVIEW FPGA – An electromechanical actuator test stand
Automated testing reduces operator man hours and increases production throughput.
Client – A manufacturer of actuators in the mil-aero industry.
Challenge
New Product Introduction (in this case a new controller and new actuators) drove the need for a new automated electromechanical test stand.
Solution
New NI PXI-based electromechanical test equipment provided automated testing, report generation, and SPC data generation. The sequencing of the test procedure, reporting, and verifiable results were managed with the StepWise test executive platform.
Benefits
- Automated testing reduces operator man hours and increases production throughput.
- Meets strict customer requirements regarding testing and data recording in a verifiable manner.
- Automated Test Report Generation.
- Collects data to support SPC (Statistical Process Control).
- Ability to obtain the internal state of the controller FPGA via the LVDS communication link.
System Overview
Viewpoint developed the software and selected NI data acquisition and control hardware for the test stand. There are several layers of software functionality.
| HOST LABVIEW SOFTWARE LAYER |
|---|
| Test sequencer |
| Test steps (e.g. Frequency Response, Step Response, Dynamic Stiffness, Fault Response, Power Consumption) |
| Test Report Generator |
| GUI |
| REAL-TIME (RT) LABVIEW SOFTWARE LAYER |
|---|
| Data acquisition |
| 1553 comms |
| Function generator |
| Error detection |
| ESTOP |
| LABVIEW FPGA SOFTWARE LAYER |
|---|
| Synch data from 3 sources (tester, UUT, external DAQ device) |
| Stream high-speed data to disk |
| Stream high-speed data to analog outputs for engineering use |
| Custom communication protocol used by UUT over LVDS lines |
| HARDWARE RECOMMENDED |
|---|
| NI PXIe |
| NI FlexRIO card with LVDS adapter module |
| Multiple NI R Series cards |
| High speed, high voltage, isolated analog input cards |
| INTERFACES / PROTOCOLS |
|---|
| MIL-STD 1553 bus |
| LVDS |
| Ethernet |
| Custom TCP/IP |
*- images are conceptual only, not actual
Creating an N-Up Tester to handle increased production volume demands
Creating an N-Up Tester to handle increased production volume demands
Enhanced throughput offers ROI payback period of less than 1 year
Client
Automotive Components Supplier / Manufacturer
Challenge
The company makes automotive components in very large volume, several part models each at more than 1 million per year.
The client’s primary concern was conserving floor space. They were completely out of spare manufacturing space.
Solution
Viewpoint created an N-up NI PXI-based Manufacturing Test System. In this case, N=6 because analysis showed that a 6-up electronic part tester allowed the test operator to cover the test time with the load/unload time.
At the high volumes needed, the client needed to parallelize as much as possible. The cost of 6 sets of test equipment and device sockets was less important than speed. Using the equation:
ProfitPerUnit x NumberAdditionalPartsPerYearAfterParallelizing > CostOfTestEquipment,
being able to completely parallelize made the number of extra units per year large enough that the payback time for completely duplicating the measurement instrumentation for each UUT socket was less than about 1 year.
Benefits
- Paid for itself in less than 1 year by the enhanced throughput.
- This approach consumed about 20% the floor space that would have been used for duplicating the test system 5 more times (for a total of 6 testers)
System Overview
Viewpoint developed an NI TestStand application that ran 6 instances of the test sequence independently of each other utilizing the duplicated PXI-based test equipment. The common parts of the overall master sequence were:
- Startup check for the entire test stand
- Shutdown of the entire test stand
- Archiving the test results into the database
Part handling was managed by a PLC and robot which delivered the parts from a tray into the UUT sockets. Digital bits were used for signaling the test sequence which parts were present in their sockets and ready to test.
| SOFTWARE FUNCTIONS |
|---|
| Test System GUI |
| Test sequencer |
| Startup checker |
| Test Results Archiver |
Increasing Test System Automation for Existing Tester to handle Production Volume Demand Increase
Increasing Test System Automation for Existing Tester to handle Production Volume Demand Increase
Reduced test time across several products by an average of ~25% and reduced time to create paperwork by ~3x
Client
Manufacturer of high-voltage power supplies
Challenge
The client already had an existing manufacturing test system in place. They wanted Viewpoint to enhance the tester due to an increase in production volume demand. Viewpoint reviewed the existing test system and noted 3 areas for improvement:
- Automation available in the measurement instruments – most of the test equipment was automatable, via some combination of serial, GPIB, or Ethernet interfaces. Furthermore, some equipment, such as an oscilloscope, had the ability to store and recall setup configurations. The test operators already used these configurations to decrease setup time for the next test step. Most test equipment did not have automated setup.
- Operator time spent on each test step – the client had been through a Lean assessment and had already done a good job of timing operations. However, we specifically noted that the operator was manually connecting to the test points and manually transcribing to paper the measurement results from instrument displays.
- Automating the connections – many types of product models were being tested at this test system. Connecting the test equipment to all sorts of products would require either 1) many types of test harnesses and connectors or 2) a redesign of the products to make test connections simpler and quicker.
Solution
The enhanced automated test system included automation of instrumentation interfaces, a test executive to run the test sequences, automated test report generation, and automated test data archiving for the electronic UUT.
Benefits
- Reduced total test time across several products by an average of ~25%.
- Time to create paperwork was reduced by ~2/3 due to automated data collection.
System Overview
The enhanced test system included the following updates:
- Test sequence automation
- Automated test report generation
- Automated test data archiving
- Automation of instrumentation interfaces
- Configurable automated test steps associated with each type of measurement instrument. The test operators would create a sequence of steps to setup each instrument and record the resulting measurement. The sequence of steps could be saved and recalled for each product to be tested, so the instruments could be used automatically.
- New programmable meter – integrated the new DMM meter with a programmable interface to replace the one that was not automatable.
- Foot switch integration – Since the connections to the test points were manual, a foot switch allowed the operator to take the measurement and advance to the next step.
The StepWise test executive platform managed the multiple test procedures created for the different products. StepWise also handled creation of HTML reports for every part tested.
| SOFTWARE FUNCTIONS |
|---|
| Test GUI |
| Test Sequencer |
| Report Generator |
| Test Data Archiving |
| Instrument interfaces |
Product Validation & Production Test System – For complex Mission-critical sub-system
Product Validation & Production Test System – For complex Mission-critical sub-system
Client
Ensign-Bickford Aerospace & Defense
Upgrade reduces per unit test time by ~40% and improves reliability of software
Challenge
The customer needed to upgrade their existing test system. Their old test system was very manual:
- It did not provide ability for unattended operation
- The thermal control had to be set manually
- They wanted to do less manual review of the data
The client develops mission-critical products, so there’s a desire to reduce manual operations because they have to explain any anomalies, and manual operations are typically more error-prone. They needed repeatable results that they could trust.
Solution
Viewpoint developed a new test system that utilized new hardware and software, augmented by existing low level hardware and firmware. The test system was developed to perform both functional test for production and environmental testing, and was designed to handle up to 4 DUTs at once. The test system utilizes the StepWise test executive software with custom test steps, which allowed the client to create their own highly configurable test sequences. The system was developed in two phases, with the second phase adding support for a FPGA expansion backplane (NI CompactRIO chassis) in order to provide future capability for bringing some of the microcontroller sequence activity into the NI space. In addition, the previous version had a mix of serial, TTL, and USB instrumentation, which was not as robust as Ethernet based instrumentation. Phase II involved upgrading to all Ethernet based instrumentation, and did away with the original test system’s many manual toggle switches that could be used instead of the programmable mode through the SW.
Benefits
- ~40% test time reduction per unit
- ~25% reduction in anomalies that needed to be justified
- ~500 manhours saved in test execution
System Overview
| Software Functions |
|---|
| Test sequencing |
| Test report generation |
| Data recording/logging |
| Error handling |
| Test GUI |
| Oscilloscope interface |
| Thermal chamber interface |
| Power supply interface |
| External custom hardware interface |
Industrial Equipment Remote Online Condition Monitoring
Industrial Equipment Remote Online Condition Monitoring
Using NI CompactRIO
Client
A manufacturer of large industrial mission-critical equipment in the electrical energy / power industry.
Challenge
Our client had three main goals in mind. They wanted to:
- Decrease unanticipated downtime and maintenance expenses
- Provide a more complete picture of machine operation and state
- Improve equipment usage tracking.
Solution
The solution is a multi-node (i.e. multi-site) remote monitoring system that utilizes an NI cRIO-based controller with customized NI InsightCM monitoring software.
Benefits
- Monitors vibration signals to predict expensive equipment failures
- Monitors current machine state via Modbus from other equipment in the system, including the primary system controller
- Provides alerts via email when any designated parameter is out of range
System Overview
The remote monitoring system monitors equipment condition by taking several vibration signal measurements along with reading over 500 Modbus registers. Local InsightCM vibration analysis on the cRIO extracts key features from the accelerometer data. Limit detection is run on these features and other equipment state and alarms are triggered when data is out of bounds. Information collected at multiple sites is sent to a central location either at periodic intervals or based on an alarm condition.
| SOFTWARE |
|---|
| NI InsightCM software |
| Modbus register configuration & reading |
| Dead banding-style register data collection to decrease amount of data captured and transferred |
| Dynamic signal data capture |
| Alarming detection |
| Data transfer scheduling |
| Semi-real-time alarm channel display |
| HARDWARE USED |
|---|
| NI cRIO |
| NI IEPE Analog Input Module |
| Microsoft Windows Server to host the NI InsightCM server software |
| INTERFACES / PROTOCOLS |
|---|
| Modbus TCP |
| Ethernet TCP/IP |
Manufacturing Test Data Logger
Manufacturing Test Data Logger
Data Acquisition System Facilitates Continuous Improvement of Product Performance
Client – A manufacturer of welding consumables
Challenge
Our client produces welding consumables. These products are inspected for continuous improvement of product performance. Our client wanted to standardize their data collection method to improve product quality and utilize SPC (statistical process control) across multiple international manufacturing facilities.
Solution
The solution is a relatively straightforward data acquisition system measuring force, vibration and voltage for comparison across multiple international manufacturing facilities to support continuous improvement of product performance.
Benefits
- Standardization of data collection across multiple manufacturing sites
- Ability to check product performance tolerances, which could trigger root cause analysis
- Ability to analyze data across product runs and across sites for SPC
System Overview
The system utilizes off-the-shelf data acquisition hardware from National Instruments along with custom LabVIEW code to perform force and vibration measurement and basic calculations such as RMS Min and Max. Each test generates an MS Word file showing summary data as well as graphs of each attribute over time. In addition, the program creates (and automatically archives) a complete data set of all data recorded during the trial and finally adds a line with all the summary results and comments to a Master log file. This Master log file can then be sorted by date, wire type, diameter, or any other input for analysis.
| SOFTWARE FUNCTIONS |
|---|
| Calculations (e.g. standard deviation, RMS, Max) |
| GUI for configuration, control, and results. |
| Automated Report Generation |
| HARDWARE USED |
|---|
| NI cDAQ |
| NI C Series voltage input module |
| NI USB Multifunction I/O Device |
| INTERFACES / PROTOCOLS |
|---|
| USB |
Custom Manufacturing Inspection System – with Machine vision and Advanced Motion Control
Custom Manufacturing Inspection System
with Machine Vision and Advanced Motion Control
Client – Xerox
Challenge
Our client had an old manufacturing inspection system (really two systems: one inspection system and an assembly/inspection system) that would no longer be supported by IT and was going to be removed from the network. They needed the operating system updated, so they decided to take this as an opportunity to port the old code from VB to C#.NET, as well as update some hardware.
As migration projects often do, this effort began by working with the client to solidify requirements, followed by a reverse engineering effort to understand the old system to try to make it match the new system as much as possible.
Solution
The updated manufacturing inspection system (one inspection system and an assembly/inspection system) included a new operating system, ported code, new motion control software, new machine vision software, and a new GUI.
Benefits
- OS Update – Updated operating system that is supported by the IT department and is less of a security risk
- Software Porting – Ported software to more maintainable language
- Measurement Accuracy – Increased inspection measurement accuracy for sub-set of measurements
- New GUI – improved operator user experience by improving readability, reducing # of required button clicks, and adding auto scroll functionality
- Report Generation – maintained existing format to interface with customer database
System Overview
The device under inspection is essentially an image sensor array used for scanning images in high end commercial-grade scanning printers. The inspection system utilizes machine vision and precision motion control to verify the location & orientation of several parts, with measurement accuracy measured in microns.
| SOFTWARE FUNCTIONS |
|---|
| Vision / metrology – pattern match and inspection |
| Camera interface |
| Motion controller interface |
| Command Recipe Decoder |
| Report Generation |
| Camera Calibration |
| Robot Controller Command Interface |
| GUI |
| HARDWARE (SELECTED & SUPPLIED BY CLIENT) |
|---|
| Cognex camera |
| ACS motion control system |
| 2-Dimensional Cartesian Robot & Controller |
| Inspection fixture |
| Power Supplies |
| INTERFACES |
|---|
| EtherCAT |
| Modbus/TCP |
Industrial Embedded Control for Advanced Manufacturing
Industrial Embedded Control for Advanced Manufacturing
Energy & Aerospace components manufacturing
Client – Automated Dynamics
Challenge
Utilize laser energy to heat thermoplastic or thermoset composite during an automated fiber placement manufacturing process.
Solution
Starting from a proof of concept developed by Automated Dynamics, Viewpoint developed the industrial embedded laser controller software for the automated fiber placement manufacturing equipment. The hardware utilized was an off-the-shelf CompactRIO controller from National Instruments.
Benefits
- High-speed temperature control
System Overview
See it in action here:
Industrial Embedded Monitoring & Control of Manufacturing Equipment
Industrial Embedded Monitoring & Control of Manufacturing Equipment
Adding Closed-loop Precision Control to Manufacturing Process with multiple international plant deployments
Client – Quantum Engineered Products Inc.
Challenge
Quantum produces manufacturing machine components that are used in the glass bottle forming process. Specifically, they supply plunger mechanisms that are used in the initial blank side formation of the glass bottle.
The engineers at Quantum recognized that they had an opportunity to improve the bottle formation process by adding position sensing to their plunger mechanisms. The ability to sense and record plunger positions would enable machine operators to monitor the travel of the Quantum plunger into the molten glass gob within the blank side mold, identify and diagnose potential hardware problems, and provide real-time feedback that could be used to better control the process.
Quantum needed a partner to implement real-time control and monitoring of the bottle forming process and selected Viewpoint for the task.
Solution
Viewpoint developed custom monitoring and control software that runs on off-the-shelf hardware. The software developed for Quantum is called TFA™ (Total Forming Analysis). The TFA™ software is a process monitor and control system for the hot side of the bottle forming process.
The software takes position information from the plungers Quantum supplies to the factories to show the travel of the tube during the forming process. The software measures key aspects of the plunger position profile such as initial plunger load position, final position, and dwell time at the final position. When these measurements are found to be out of tolerance, the software communicates with the machine auto-reject system to ensure that bad bottles are removed from the system.
Moreover, the final plunger position is used as feedback to do closed loop control of the glass gob weight, controlling glass feeder tube height and/or needle heights to change the glass gob weight. This allows for precise control of container weight, making the most efficient use of raw materials while ensuring container quality.
To accommodate multiple end-customer-driven hardware configurations, the off-the-shelf hardware selected was based on the National Instruments CompactRIO family of chassis to enable configuration of various input/output signal requirements.
For the end result, check out one of the machines running TFA™ in action:
Benefits
Hardware Customization Flexibility – every one of Quantum’s customers wants something either a little or a lot different with their particular instance of the system. Using modular hardware allowed for swapping of I/O hardware.
Quick Response to Software Feature Requests – Quantum and Viewpoint were in constant communication to be able to implement new features and tweaks on fairly short notice (generally within a couple of weeks).
On-Site Support – Viewpoint engineers travel to Quantum’s customer sites with them as a team upon request.
System Overview
The embedded process monitoring and control system consists of custom process monitoring and control software that runs on off-the-shelf hardware.
| NOMINAL HARDWARE |
|---|
| NI 9148 Ethernet expansion chassis |
| NI 9201 module for AI |
| NI 9425 module for DI |
| NI 9476 module for DO |
| SOFTWARE FUNCTIONS |
|---|
| Data Acquisition and Processing |
| Waveform Calculations (eg. final position and dwell time) |
| Final Position control loop |
| Real-time per cavity plunger position graphs |
| Process trend graphs |
| Forming history graphs, showing a packet of the last forty final positions per cavity |
| Limits definition screens |
| System health summary, fault monitoring and auto-reject configuration |
| Job configuration |
| Plunger sensor calibration |
| COMMUNICATION INTERFACES |
|---|
| Gb Ethernet communication with the DAQ devices (NI 9148 chassis) |
| TCP/IP Modbus communication with Schneider Electric motors for feeder tube and/or needle control |
TFA™ is a registered trademark of Quantum Engineered Products, Inc.
How to select a LabVIEW consultant
Maybe you’re LabVIEW programmer quit or retired, or maybe you’ve got some internal capabilities but need some additional support because everyone’s too busy. From hourly rates to a range of skills, there are several factors to consider. We’ll help you weigh each one. See How to Select a LabView Consultant.
LabVIEW developers: local vs remote
Headquartered in Rochester NY, we help customers all over the U.S. See the Pros and Cons of a local vs remote supplier for LabVIEW-based test system development.
3,000+
LabVIEW solutions deliveredGreat for automated measurement & control: manufacturing test, product validation, machine control and condition monitoring.
700+
LabVIEW FPGA systems deliveredGreat for applications requiring seriously deterministic timing, reliable code execution, and multi-channel synchronized processing.
1,000+
LabVIEW RT systems deliveredThe combination of LabVIEW RT and the RTOS on which it runs allows for the creation of applications with bounded jitter and latency.
500+
cRIO-based systems deliveredCombining a cRIO controller with the multitude of C Series modules creates a functional real-time controller in a small footprint.
1,500+
PXI-based solutions deliveredBroad range of off-the-shelf expansion cards & processing horsepower make PXI a formidable choice for many automated test applications.