Customer Centric Solutions:

PROJECT: Broaching System Equipment Upgrade

CLIENT CHALLENGE: 
The client needed to improve the speed of operation of its broach machine. The existing control system had antiquated hardware, and a problematic sequence of operation that was complicated to troubleshoot, especially with over 300 analog and digital I/O points. The client could not afford to be without the operation of the machine for a prolonged period of time for upgrading.

TRI-STAR AUTOMATION SOLUTION:

We operated in 24-hour rotating shifts to re-program the entire system to speed up its processes, accomplishing the task in a single weekend.

THE NEW SYSTEM FEATURED: Colour HMI touchscreen display with pre-programmed set-point alarms and diagnostics to reduce both downtime and setup and a maintenance manual that documented electrical schematics, parts list, PLC program and touch screen program.

Customer Centric Solutions:

PROJECT: Coil Line Machine Upgrade

CLIENT CHALLENGE:

The client was troubled by an outdated conventional relay control system with approximately 150 I/O points.

TRI-STAR AUTOMATION SOLUTION: 
We replaced the antique relay control system with a fully integrated PLC system. New custom programming was written that improved the quality of the machine and the cycle time. In addition, encoders were implemented in order to improve the positioning accuracy of the material. Lastly, a new HMI screen was programmed and installed for the operator complete with set points, alarms and diagnostics.

The entire upgrade was executed during regular business hours in under a week.

Customer Centric Solutions:
 

PROJECT: Rollover 3B, 4B Equipment Upgrade

CLIENT CHALLENGE: The client was burdened with antiquated hard wired relay control systems. Each one used 120 digital inputs and outputs to control rotating heavy steel wheels.

TRI-STAR AUTOMATION SOLUTION:

The extreme weight of the massive steel wheels being controlled, and the subsequent high inertia they exert-
ed on the drive motors, required us to specify and implement new variable frequency drives with dynamic braking to increase both speed and braking abilities. Each hard wired relay control system was replaced with a fully integrated PLC system complete with HMI screen display with set points alarms and diagnostics.

To minimize impact on production, the entire changeover was completed in a single weekend through the utilization of around the clock shifts.

Customer Centric Solutions:

PROJECT: Straightener System Equipment Upgrade

CLIENT CHALLENGE: 

The client’s existing straightening system was bottlenecking their entire line of production. It was hindered by an obsolete PLC system, containing 700 analog and digital I/O’s, and a measuring system lacking in repeatability and accuracy. The system was complicated to maintain and diagnose problems.

TRI-STAR AUTOMATION SOLUTION: 
We provided a total turn-key system that first transferred all points to a new Schnieder PLC system and then completely re-engineered the logic to improve efficiency at all points along the entire line of production.

THE NEW SYSTEM FEATURED: 
Two three-point measuring systems that determined horizontal and vertical straightness of rails to within 1/1000th of an inch to improve accuracy; four hydraulic cylinders controlled by hydraulic proportional valves with analog feedback to speed up production and colour HMI touchscreen display with pre-programmed set-point alarms and diagnostics to reduce both downtime and setup. Lastly, the entire system was thoroughly documented with a new maintenance manual that included electrical schematics, parts list, PLC program and touch screen program.