PLC automation
Automatic sorting line for laboratory samples
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Decuna delivered to a laboratory as a "turn-key" installation an automatic sorting line for milk samples. The project was managed end-to-end, from requirements capture, desing, manufacturing, integration and commissioning, including robot tooling desing and robot integration.
The sorting line is multi-purpose:
- first of all, the samples need to be placed on plastic pucks, so that they can be conveyed
- data acqusition is needed, reading the barcode on every sample and introducing the data in the system
- finally, the samples are grouped by test type, unloaded from the pucks into the racks
Solar plant control software dec-solar
dec-solar is the maintenance-free software control package for solar energy plants. dec-solar reports alarms and controls the plant. Relevant plant data are logged and represented in reports:
- power produced (total / per inverter)
- solar tracker position control
- weather conditions at the plant
- manual control of the solar trackers and calibration
The data can be presented in a web page or alternatively access can be granted via a secure terminal connection. The data can be stored locally or in a remote server. In case of too harsh weather conditions, dec-solar sets automatically the panels to safe position.Â
Maintentance free solar tracker controllers: dec-trac series
Decuna's dec-trac solar tracker controllers have been designed to minimize installation costs and spare maintenance in solar power plants.
dec-trac is robust, low-cost, and uses standard components. It is conceived for mass production. Several versions have been adapted to different solar tracking modes:
- electric or hydraulic drive
- roof-top mount or ground installation
- 1-phase or 3-phase motors
- tracking in 1 or 2 axis
- standalone or central control
- open control loop or closed control loop (with encoder o inclinometer)
dec-trac is accurate (0,001 degrees) and suitable for demanding applications such as heliostats (solar tower technology) or concentrated photovoltaic power (CPV).
dec-trac can even control the inverters, using just one control network with ring topology for reliability and redundancy. It integrates seamlessly with the control software package dec-solar, visualizing the actual plant state and extracting relevant data with reporting tools.
Automated storage system for an automotive seat supplier
Decuna worked together with a counterpart responsible for mechanics developing an automated storage system for an automotive seat supplier.
An automated storage and retrieval machine and a buffer for the products were automated.
The system saves an important amount of storage space and allows our customer to meet not only "Just in Time" requirements, but also "Just in Sequence" (delivering the sequence that the OEM is going to build in the production line).
Bacteriological milk analysis automation
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Decuna automated the milk sampling for plate culture with existing equipment, implying an important cost save for the laboratory.
The racks with milk samples are loaded on the left side of the machine by the operators. The samples are conveyed to the centre, so that the pipette rack prepares the plates for culture.
Once the culture samples are taken, the samples are transferred to the right side of the machine, ready to be unloaded.
Both milk samples and culture plates are identified with a barcode. Severar barcode readers were placed to read the data in the barcodes. A computer stores the barcode data in a database and matches them, so that total traceability can be guaranteed in the sampling process.
In case of a positive analysis, the software can inmediately track:
- where the original sample is (if a cross-check is required)
- the farm where the sample was produced
- the animal that originated the sample
Temperature control software for pharmaceutical warehouse according to GMPs
As a part of a global process reform in a biopharmaceutical producer, Decuna implemented software for HVAC temperature control of the warehouse zone.
The software was developed for different Rockwell PLCs, strictly aligned with common practices in the pharmaceutical industry, such as GMP/GAMP5®. The software deployment was successfully coordinated with other ongoing reforms in the plant.
Automated pallet storage with aisle and row carts
An alternative to "store-and-retrieve" automated warehouses is an automated pallet storage system with aisle and row motorized carts.
This system handles high production throughput in a small space, and it has a very high storage density, optimizing space and stacking multiple pallet sizes at the time.
An automated truck loading system (ATLS) reduces delivery time using less manpower, less door docks and reducing product damage. This system was also integrated by Decuna in the warehouse with the rest of the system.
A video is available here:
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Palletizer robot - Cardboard boxes with variable size
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Decuna delivered and integrated in the production system a palletizer robot for carboard boxes with variable size for an automated warehouse. In the automated warehouse there are multiple references, carboard boxes with different size and weight, containing different items such as small household electric appliances and clothing.
The warehouse had demanding requirements in terms of output rate, which is completely handled by the robot
Therefore, Decuna designed the robot gripping system, versatile and robust, that adapts perfectly to every system reference. The system admits two kinds of pallets: 800x1200 and 1000x1200. The pallet layout depends on the references placed, and the robot can handle even incomplete pallets and pallets with several references.
Our supply included a system to configure the type of references to be picked and palletized, production setup and security systems such as emergency stops and light curtains with muting according to industry standards.
Welding paste automated application with robot
This robot applies weling paste for automotive coolers. The special welding paste achieves a high quality finish in the parts. After the welding paste is applied, the parts are treated with heat in an oven, that melts the paste and welds the components.
The paste needs to be applied accuracely. There is a high variabilty along the production process, because of the nature of this special paste. It needs to be calibrated after certain periods of time.
This operation was done previously by a skilled worker.
The robot introduces improvements in the process:
- repeatability
- cost save
- automatic paste calibration
Decuna developed this work under the "turnkey" concept. We dealt with mechanical design, supplier management, integration, production start and support all over the process.
Application video
The application can be seen in this video from different angles. A special tooling applies the paste in the inner side of the part, and the robot impregnates the outer side. The complete piece contour is covered with the robot arm movement and the paste nozzle.
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Steering wheel assembly machine and integrated tester
While the final product (steering wheel) is assembled, a mechanic and electric test is being performed. The application also integrates with the ERP at the customer's site providing traceability information.
The tests to be performed are:
- electrical contacts, continuity
- horn
- color,
- product type,
- element presence check
- screw torque check
A barcode reader is veryfing product batch and sequence. The PanelPC is generating the production orders and ensuring product traceability
Similar machines were installed in other locations:
- TRW Timisoara (Romania)
- Dalphi Metal (Portugal)
