Legacy Control System Upgrade for Steel Manufacturing

Solution by: Prolucid Technologies Inc


A cRIO based solution for high speed fault inspection monitoring for a legacy steel shear line.

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A NI cRIO and FPGA solution for high speed monitoring on a steel shear line inspection system. Using the FPGA to read the incoming legacy position signals we were able to visually show the exact location of the fault and keep that location tracked therefore reducing the need to reject parts that may have a fault. Since we were able to tie the existing legacy sensors with the NI cRIO we were able to greatly reduce down time for the switch over. By using the cRIO and FPGA we were able to provide a simple UI that the operators were able to quickly understand to help ease the transition of a system that had been in place for many years.

Features
  • By using the cRIO and FPGA we were able to provide a simple UI that the operators were able to quickly understand to help ease the transition of a system that had been in place for many years
  • The flexibility of using cRIO with LabVIEW in this solution, has provided a fast development platform, with excellent capabilities to connect to legacy instruments and create a robust solution and simple UI
Benefits
  • Using existing sensors and fault detection methods we were able to provide a solution to improve false positives by 66%
  • Since the legacy system wasn't able to keep track of exact locations, or previous runs this caused for many good parts to be rejected for fear of a bad part getting shipped to the customer
  • By reducing the amount of rejects the customer was in turn able to save 40 hours of labour per week that was previously used to retest the rejected parts
  • By reducing the amount of rejects the customer was in turn able to save 40 hours of labour per week that was previously used to retest the rejected parts
NI System Content
  • cRIO-9068
  • NI-9411
  • NI-9423
  • NI-9485
  • LabVIEW 2013 PC/RT/FPGA

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