Background:
Our customer manufactures pumps for industrial applications. They approached Scott Industrial Systems for two test systems, one to replace an existing test cell, and the other is brand new for the facility to test additional water pumps.
Challenge:
The client’s test system collects data of their water pump’s performance with either a hydraulic or electric motor. The customer provided detailed specifications for tests, HMI screens, and “the mechanical envelope” for the system such that the unit would fit within the dimensions of the test cell.
Methodology:
The customer needs to test different types of pumps, so Scott Industrial implemented a modular solution. Our control solution can connect to an electric motor or a hydraulic motor, depending on the test.
Our customer was very specific about data collection for each pump. They wanted to implement test collection, so Scott designed a system utilizing a barcode scanner and operator number to save test data and analyze results without the need for manual input. This process provides real-time graphing through the HMI unit. This data feeds back to the server network for reports and quality control. Their team can connect remotely to the system from any location. Engineers can pull up test data, set up, adjust their test in real time, and set up new recipes for every new product. Formerly, this process involved connecting the motor to gauges and manually recording data with pen and paper.
In the new system, they can manufacture a pump, bring it into the test cell, and secure it to a hydraulic or electric motor. A recipe screen loads all of the test parameters into the PLC, including pressures, times, and speeds. Once the operator hits the “Start Test” button, the program takes over to perform a low-speed test and then a high-speed test. They can either save the data or repeat the process. Scott Industrial’s system controls the power unit which runs the hydraulic motor and the electrical panel and VFD for the 150 HP electric motor.
Result:
The processor selected is specifically chosen for data logging. It has built-in functions that allow it to connect to the customer’s server. Each of these systems has its own panel that communicates using one EtherCAT cable so there is no wiring back-and-forth on the system. One panel communicates via the network to separate valve panel while another controls the speed. This creates easy and safe installation for electrical contractors. They only need two high-voltage drops for each test cell and two cables between each box.
An old system would have had one main panel and several conduits of control wiring and installation expense and panels. Instead, we use multiple small panels and remote inputs and outputs that can communicate easily.
Founded in 1948, Scott Industrial are experts in fluid power. We offer design and assembly services as well as training to help customers maintain optimal equipment performance.
To learn more about Scott Industrial Systems’ capabilities visit http://www.scottindustrialsystems.com/. To discuss our efficient and collaborative approach to your project, call 937-233-8146 or e-mail us at sales@scottindustrial.com.
