Mine Power Succefully completed Project Case Studies - "Efficiency Starts Here: Integrated Control Panel Solutions for Industrial Automation"
Project - Hydraulic Load Testing Equipment for Skyroot Aerospace Rocket Components
Project - Hydraulic Load Testing Equipment for Skyroot Aerospace Rocket Components
Description: Our project involves the design and development of a hydraulic load testing equipment specifically tailored for Skyroot Aerospace’s rocket components. The system utilizes various components such as DELTA PLC (Programmable Logic Controller), DELTA HMI (Human-Machine Interface), load cells, controllers, and LVDTs (Linear Variable Differential Transformers).
The hydraulic setup enables load testing of aerospace components up to 8 tons in both compression and tension. It employs hydraulic cylinders as hydraulic actuators, converting hydraulic energy into linear mechanical movement. Similar to muscles, the hydraulic cylinder generates movement within the machine’s hydraulic system.
Load cells play a crucial role in the setup, converting forces (tension, compression, pressure, or torque) into electrical signals that can be measured and standardized. They act as force transducers, with the electrical signal changing proportionally to the applied force. In our setup, we utilize a hydraulic load cell design, employing a piston and cylinder arrangement with a thin elastic diaphragm. The diaphragm experiences an increase in oil pressure when the load is applied to the piston, which is then transmitted to a hydraulic pressure gauge via a high-pressure hose.
Additionally, the setup incorporates LVDTs as absolute linear position/displacement transducers. These robust and frictionless transducers convert mechanical position or displacement into proportional electrical signals, providing phase and amplitude information. LVDTs have excellent repeatability and can operate in harsh environments, making them suitable for applications in aerospace, power turbines, hydraulics, and more.
Our team has carefully designed and built control panels using DELTA PLC and DELTA HMI to ensure precise control and monitoring of the load testing process. With our equipment, Skyroot Aerospace can perform accurate load testing on their rocket components, ensuring their reliability and performance in demanding aerospace applications.
Title: Auto Batching Plant for Fly Ash Bricks
The Auto Batching Plant for Fly Ash Bricks aims to automate the production process of high-quality fly ash bricks with high pressure. The plant consists of a mixing unit, compression unit, curing system, and drying system. It is designed to produce 500kg of brick mix in just 1 minute, with the capacity to manufacture 1000 to 3000 bricks per hour. The project utilizes mechanical data and automation technologies such as Delta PLC, VFD, HMI, and SCADA to achieve efficient and reliable operation.
Solution: The solution involves the design and construction of an auto batching plant specifically tailored for the production of fly ash bricks. The plant incorporates a pan mixer that blends the raw materials, including fly ash, lime, gypsum, and sand, in desired proportions for 4-5 minutes. The mixture is then compressed under high pressure to form the bricks. A curing system ensures the bricks gain strength over a minimum period of 14 days, followed by a 7-day air drying process. By varying the compositions, the strength of the bricks can be engineered.
- Design and fabrication of the auto batching plant, including the mixing unit, compression unit, curing system, and drying system.
- Integration of automation technologies such as Delta PLC, VFD, HMI, and SCADA for machine control and monitoring.
- Procurement and setup of required equipment and materials.
- Testing and calibration of the plant to ensure accurate batching, compression, curing, and drying processes.
- Training of operators on the operation and maintenance of the auto batching plant.
The implementation of the auto batching plant for fly ash bricks offers the following results:
- Efficient production of 500kg of brick mix in just 1 minute.
- Increased productivity with the capacity to manufacture 1000 to 3000 bricks per hour.
- Consistent quality of fly ash bricks due to controlled mixing, compression, curing, and drying processes.
- Reduction in manual labor and time required for brick production.
- Improved strength and stability of the bricks, enhancing their durability and longevity.
- The auto batching plant for fly ash bricks enables high-speed production and consistent quality.
- Automation technologies enhance efficiency, accuracy, and control in the manufacturing process.
- Fly ash bricks offer advantages such as durability, fireproofing, and cost-effectiveness compared to other construction materials.
- However, the construction process can be time-consuming, and bricks have limitations such as susceptibility to high seismic pressure and water absorption.
By integrating automation and advanced manufacturing techniques, the auto batching plant for fly ash bricks presents a modern and efficient solution for the construction industry.
Title : Leak Test Equipment for Automobile & Aero Space Components -upto 0-100bar to LGB Indoshell
The project involves the design and development of leak test equipment for automobile and aerospace components. The equipment is capable of conducting leak tests ranging from 0-100bar and is suitable for LGB and Indoshell components. The solutions provided can vary from simple, manually connected leak test fixtures to fully automatic, robotic, and high-speed production facilities. TQC, based in Nottingham, UK, specializes in designing and developing leak testing equipment tailored to the specific requirements of customers in various manufacturing sectors worldwide.
The implementation of the leak test equipment involves the design and development of customized fixtures and sealing mechanisms based on the customer's requirements. TQC utilizes its in-house design facilities and combines them with standard leak test instruments to create a tailored solution. The equipment can be integrated into existing production lines, whether manual or fully automated, ensuring a seamless integration process.
The leak testing equipment provides quantifiable results, allowing manufacturers to verify the integrity of their products against specified leak limits. The calibration to relevant standards ensures accuracy and reliability in detecting leaks. The implementation of automated pass/fail limits and marking streamlines the testing process, increasing efficiency and productivity. The availability of data outputs for SPC analysis enables manufacturers to monitor and improve their production processes.
Project Name: CNC Controller and Automation System Integration
The project aims to integrate a CNC controller and automation system into a machine tool to enhance its functionality and productivity. The CNC controller, consisting of electronics and software, plays a crucial role in converting input commands into motor signals, enabling precise control of the machine's axes. By retrofitting older machines with the necessary components, the CNC system can be implemented to automate various machining processes. Additionally, the inclusion of sensors allows for real-time decision-making and monitoring, further enhancing the machine's capabilities.
- CNC systems comprise a control unit, motion-control system, and sensors.
- Retrofitting older machines with CNC components is a common practice.
- CNC controllers convert input commands into motor signals.
- Sensors enable real-time decision-making and monitoring during machining.
The solution involves integrating a CNC controller and automation system into the existing machine tool. This process includes the installation of the control unit, motion-control system components (such as servomotors, drives, and axis positioning devices), and appropriate sensors. The CNC controller's software is configured to interpret input commands, generate motor signals, and provide the necessary instructions for the machine's operations. The integration process ensures seamless communication between the CNC system and the machine, enabling precise control and automation.
- Assess the machine tool:
Evaluate the compatibility and feasibility of retrofitting the machine with a CNC controller and automation system. Consider the mechanical and electrical modifications required.
- Procure CNC components:
Purchase the necessary CNC components, including the control unit, motion-control system components, and sensors. Ensure compatibility with the machine tool and its specifications.
- Mechanical integration:
Install the motion-control system components, such as servomotors, drives, and axis positioning devices, according to the machine's mechanical configuration. Make any required adjustments or modifications.
- Electrical integration:
Connect the CNC controller to the machine's electrical system, ensuring proper wiring and connections. Follow the manufacturer's guidelines and specifications for integrating the electronics.
- Sensor installation:
Install sensors, such as probes for measuring part position or machined features, and monitoring systems for tool presence and cutting force. Calibrate and configure the sensors according to the CNC controller's software requirements.
- CNC controller software setup:
Install the appropriate CNC control software on the control unit. Configure the software settings, including motor control parameters, input/output configurations, and toolpath interpretation.
- Testing and optimization:
Validate the integration by conducting thorough testing. Verify the CNC system's functionality, including motor movements, sensor accuracy, and real-time decision-making capabilities. Optimize the system as needed to achieve desired performance.
The integration of the CNC controller and automation system into the machine tool yields several benefits. These include:
- Enhanced precision and control over machining operations.
- Automation of repetitive tasks, reducing manual intervention and increasing productivity.
- Real-time decision-making capabilities for unattended or lightly attended processes.
- Improved monitoring of tool presence and cutting forces, contributing to safer machining operations.
- Compatibility with industry-standard G-code commands and CNC control panel inputs.
- Potential for future upgrades and expansion of the CNC system's capabilities.
- Integrating a CNC controller and automation system enhances machine tool functionality.
- The process involves mechanical and electrical integration, along with sensor installation.
- CNC controller software configuration is crucial for proper operation.
- The integration results in improved precision, productivity, and safety.
- The system is compatible with industry-standard commands and allows for future upgrades.
Title: Textile Cloth Winding Machine Panel
This project focuses on the development and implementation of a textile cloth winding machine panel. The panel utilizes Siemens Variable Frequency Drives (VFD) and Programmable Logic Controller (PLC) programming with analog controlled sync.
- Development and implementation of a textile cloth winding machine panel
- Utilization of Siemens VFD drives and PLC programming
- Analog controlled sync for enhanced control and synchronization
The solution involves designing and constructing a dedicated panel for the textile cloth winding machine. The panel integrates Siemens VFD drives to regulate the rotational speed of the machine, ensuring optimal performance and efficiency. The PLC programming, combined with analog controlled sync, enables precise control and synchronization of the winding process, resulting in high-quality and uniform textile cloth winding.
The implementation process includes the following steps:
- Designing the electrical panel layout, incorporating Siemens VFD drives and necessary control elements.
- Programming the PLC to control various machine parameters, such as speed, tension, and synchronization.
- Integrating analog controlled sync to ensure accurate coordination between different sections of the winding machine.
- Testing and fine-tuning the panel to ensure reliable and efficient operation.
- Installing the panel on the textile cloth winding machine and conducting thorough system integration tests.
The implementation of the textile cloth winding machine panel has yielded several positive outcomes:
- Improved control and synchronization of the winding process, leading to enhanced product quality and uniformity.
- Higher efficiency and productivity due to optimized speed regulation and tension control.
- Reduced downtime and maintenance costs through the integration of reliable Siemens VFD drives.
- Enhanced operator interface and user-friendliness, enabling easy monitoring and adjustment of machine parameters.
- The textile cloth winding machine panel successfully integrates Siemens VFD drives and PLC programming with analog controlled sync.
- The implemented solution improves control, synchronization, and overall performance of the winding process.
- The project demonstrates the effectiveness of utilizing advanced automation technologies in textile manufacturing applications.