Case Histories...


Project Case Studies
APC has successfully completed projects in many industries utilizing a large number of different technologies. The following is a synopsis of the type of work that we are capable of and confirms our solutions based approach.



Problem: Loss of production due to manual loading of crusher system.

Solution: Design and build of advanced control system to automate the feed and operation of hydraulic crusher. Consequently, production increased and the customer realized a significant cost saving.

Technology Used: Allen Bradley PLC integrated into the existing control system and communication to field devices over an Interbus bus system.

Problem: Product quality problems caused by poor operator monitoring and lack of data logging system.

Solution: To replace unreliable human eyes, an eight camera real time vision system was designed and implemented by APC. The system incorporated PC based control and logging of production. Thus, final product quality was greatly improved and the image logs produced provide valuable manufacturing data. The system is very versatile and the same technology has been successfully used in many industries to replace visual quality checks carried out by human eyes.

Technology Used: CCD video cameras, PLC based controls, Siemens HMI and PC based image recording.

Problem: Operator errors caused by incorrect part selection leading to poor productivity and wastage of good parts.

Solution: Design and installation of automatic part identification system to ensure correct part selection. The system features mechanical and electrical interlocks to prevent the operator selecting and fitting the wrong part for the item in production. A system of lamps indicates which part is to be selected, a sensor on the part bin further ensures correct part selection. Thus correct part selection is ensured and costly wastage eliminated.

Technology Used: PLC based controls, remote I/O, Serial interface into existing controls.

Problem: Verification of product ageing performance to ensure correct life of the finished product.

Solution: Design and installation of roofing panel accelerated ageing test rig with real time vision system to monitor results. The project required a rapid turnaround to meet production levels as well as power monitoring and control.

Technology Used: IR heat lamps with closed loop control and re-circulating water cooling system. Siemens PLC and HMI. PC based camera monitors and data logging. The system is fully automatic, no operator is required thus a large cost saving was realised.

Do you have a problem in your production process? We have the expertise to improve your productivity. Contact us.