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The manufacturing industry is constantly evolving, with new technologies and processes being developed to improve efficiency and productivity. However, integrating new equipment into existing manufacturing systems can be a challenge, particularly when it comes to ensuring that the new equipment works seamlessly with the existing equipment. Here are some tips for overcoming equipment integration issues for the manufacturing industry:

Plan Ahead

One of the most important things to do when integrating new equipment into an existing manufacturing system is to plan ahead. This includes identifying any potential integration issues and developing a plan to address them. It is also important to consider the impact that the new equipment will have on the existing system, including how it will affect workflow, output, and efficiency.

Test the Equipment

Before integrating new equipment into an existing manufacturing system, it is important to test the equipment thoroughly to ensure that it works as expected. This includes testing the equipment in different conditions and scenarios, and testing its compatibility with other equipment in the system. Any issues or defects should be identified and addressed before integration, to avoid any potential problems down the line.

Involve the Team

Integrating new equipment into an existing manufacturing system can be a complex process, involving multiple departments and stakeholders. It is important to involve the entire team in the integration process, including operators, technicians, and managers. This will ensure that everyone is aware of the changes and can provide input on how best to integrate the new equipment into the system.

Communicate Clearly

Clear communication is essential when integrating new equipment into an existing manufacturing system. This includes communicating with equipment vendors, suppliers, and other stakeholders to ensure that everyone is on the same page. It is also important to communicate with employees, to ensure that they understand the changes and are prepared to adapt to the new equipment.

Provide Training

Integrating new equipment into an existing manufacturing system often requires employees to learn new skills and processes. Providing training is essential to ensure that employees are able to operate the new equipment effectively and efficiently. This can include training on the equipment itself, as well as training on any new processes or procedures that may be required.

Monitor Performance

Once new equipment has been integrated into an existing manufacturing system, it is important to monitor its performance to ensure that it is working as expected. This includes monitoring output, efficiency, and any potential issues or defects. Any issues should be addressed promptly, to avoid any negative impact on the overall system.

If you’re looking for a trusted and professional controls integration company, contact RL Consulting today. 

In industrial automation, Programmable Logic Controllers (PLCs) and Programmable Automation Controllers (PACs) are both popular choices for controlling and monitoring manufacturing processes. While both types of controllers are designed to perform similar functions, there are some key differences between the two that should be considered when deciding which one to use for a particular application.

Here are some factors to consider when deciding between a PLC and a PAC:

Control Requirements

PLCs are typically used for controlling simple processes with discrete inputs and outputs, such as turning on and off pumps or conveyor belts. PACs, on the other hand, are designed to handle more complex processes that require advanced control algorithms and data processing capabilities.

Scalability

PLCs are generally more cost-effective for smaller applications that require a few I/O points. However, if the process is expected to grow and require additional I/O points, a PAC may be a better choice as it can easily scale up to handle larger applications.

Programming Language

PLCs use ladder logic programming language, which is easy to learn and use, especially for those with a background in electrical wiring. PACs, on the other hand, can use a variety of programming languages, including Structured Text, Sequential Function Chart, and C/C++, making them more flexible and powerful.

Networking

PACs typically have more networking capabilities than PLCs. They can communicate with multiple devices and systems, including databases, servers, and other controllers, using a variety of protocols. PLCs, on the other hand, are more limited in their networking capabilities and are typically used for point-to-point communication.

Data Handling

PACs are designed for handling large amounts of data and processing it quickly. They can perform complex data analysis, store data in databases, and generate reports. PLCs, on the other hand, are not as well suited for data handling and analysis.

Redundancy

PACs offer more redundancy options than PLCs. For critical applications where uptime is crucial, PACs can be configured with redundant controllers and network connections, ensuring that the process continues to operate even if one component fails. PLCs, on the other hand, are typically used in applications where redundancy is not as critical.

Cost

PLCs are generally less expensive than PACs, especially for smaller applications. However, the cost difference between the two can vary significantly depending on the specific application and the required features.

In conclusion, deciding between a PLC and a PAC comes down to a number of factors, including the complexity of the process, scalability requirements, programming language, networking capabilities, data handling requirements, redundancy options, and cost. It is important to carefully evaluate these factors and choose the controller that is best suited for the specific application. Ultimately, both types of controllers can be effective solutions for industrial automation, and the decision between them should be based on the specific requirements of the application.

Data from industrial operations is commonly obtained through devices such as switches, sensors, and input/output modules. This data can also be obtained through higher level devices such as remote terminal units (RTUs) and controllers. The data makes its way to a SCADA (supervisory control and data acquisition) system, whose primary function is data acquisition and data logging. The SCADA system captures and transforms the data, which can be used for other purposes such as fault detection. An HMI (Human-Machine Interface) system is used to transform the data into visualizations such as graphs, data charts, pictorials, tables etc. Thus leading to an easier understanding from operators.

Digital transformation is a part of our reality today, with technology constantly developing and changing, using industry standard 64-bit servers for data logging is essential for future-proofing the system. Below are 10 modernized SCADA system features to keep your servers moving forward. 

Universal Connectivity

SCADA systems should be utilizing universal connectivity, which allows users to connect to any data system from anywhere. The system should also allow users to use business systems to integrate data. 

2D and 3D Visuals

Your SCADA system should provide scalable and secure visualizations on mobile devices, browsers, and desktops at a fast pace. Also, it should support WPF and script-less HTML5 technology which allows for consistent visuals on pretty much all platforms. 

Self-Service Dashboards

Self-service KPI (key performance indicators) dashboards allow management to understand the big picture from an operational standpoint at any given time, and quickly. A few things this system also allows users to do include: dragging and dropping data, split screens, configure widgets, process points and trends and alarms, and leverage preconfigured gauges. At a very minimum, the SCADA system should provide on the spot display creation to visualize the data when it is needed and where it is needed. 

Energy Monitoring 

Being able to visualize, summarize and aggregate energy consumption and usage in real-time is another feature your SCADA system can provide. Secure, mobile-friendly dashboards are used for energy monitoring, to make understanding the data easier. 

SMS & Email Alerts

Most SCADA systems should at a minimum be able to deliver alerts via text messages or email, but most desirably would be able to distribute email, voice, text-to-speech, instant messaging and other collaboration platforms enterprise-wide. This means quicker access and communication to a larger number of people. 

If you’re looking for a SCADA integrator, contact RL Consulting Inc. today.

RL Consulting Inc. is an electrical control systems integrator based in Muscle Shoals, Alabama but serving the United States. Founded in 2003, we have almost 20 years of experience providing customers quality solutions in a variety of control systems. We work with various different industries including Pulp and Paper, Steel, Textiles, Automotive, Manufacturing and more. Learn more about the products and services we offer below. 

Electrical Controls Design

Our electrical controls design team can design systems that integrate seamlessly into systems that are already in place. With our team having over 20 years of experience, we have interacted with a variety of different manufacturing processes. We will work with you to determine your goals and develop solutions to meet those needs. 

PLC Programming

RL Consulting Inc. has years of experience writing and programming PLC programs. To name a few of the top manufacturers we use: Allen Bradley, Mitisubishi, Siemens, GE, and Omron. We can develop customized applications using a variety of programming languages. If you’re looking for a PLC Programming Company, contact us today. 

CAD Drafting of Electrical Systems

We use AutoCAD Electrical to ensure all of our projects are well documented. An accurate drawing helps ensure a smooth installation. If you are in need of up to date drawings, we can complete a drawing package for you after a field survey is complete. Our draftsmen can complete your task in a timely manner. Learn more here. 

Electrical Panel Design and Build

All design and construction of our electrical panels is done in house. Our systems are also fully tested prior to being shipped to reduce start up times. We provide CAD based electrical schematics with all of our electrical panels as well. Learn more about our electrical panel design and build service here. 

RL Consulting Inc. is your trusted control systems integrator and PLC programming company. If you would like more information about any of our services such as electrical panel design, CAD Drafting of Electrical Systems or more, contact us here. 

Industrial automation would not be possible without control system integration. Factories, manufacturing plants, and many more depend on control system integration to operate daily. There are five critical factors involved in industrial control system integration, read more below. 

Software Infrastructure

Software infrastructure is important for system integration because modern automation systems need configuration, monitoring, AND integration. OPC-UA technology, designed by OPC Foundation, is designed to provide clients with real-time, historical data exchange and simpler browsing. This technology also allows integrators, such as RL Consulting Inc., flexibility to integrate desired configurations for a wide range of different systems, instead of being locked into a specific setup. 

Process Database

There are three main components that the database primarily includes: tables for the data, forms for entering or displaying data, and a query language. Customized page views of data and reporting tools are additional components that may be included. A DBMS (database management system) collects interrelated programs files and allows users to modify files. A query language such as SQL is used to interact with a DBMS. Basically, a database is a collection of different items used to view, process, and access data. 

Human-Machine Interface

HMI (Human-machine interface) means operators have the benefit of treating a machine much like they would a human worker. This includes monitoring the state of a control process and issuing commands to change that objective. It can also be used to manually override automatic controls in an emergency situation. Graphics, historical trends, reports, scripts and alarms are all primary aspects of HMI. 

Alarm Management

When integrating different control systems, alarm management is critical because they are designed to alert operators when there are critical issues. Alarms are used to mark the boundary between abnormal and normal conditions in the process. In order to be effective they need to be relevant, prioritized and timely. 

Network Security

With organizations increasingly sharing information between industrial and business systems, ICSS (Integrated Controls and Safety Systems) operate alongside each other within a complex environment. Industrial systems that include safety systems, process control systems, and PLCs (programmable logic controllers) rely on off the shelf products such as Microsoft Windows, Ethernet, and TCP/IP for noncritical and critical functions. However, in the event of a security breach, there is more worry surrounding the loss of production life, environmental damage, and operational safety than losing any trade secrets. 

RL Consulting Inc. is a controls integration company specializing in PLC Programming, integration and more. If you would like to talk more about programming your PLC, contact us today. 

With the rise of automation, PLC controllers have become more popular than ever. PLCs are a good choice for a variety of reasons. A PLC controller is a programmable logic controller, which is a type of industrial automation device. PLCs are used in a wide variety of industries, from manufacturing to utilities. PLCs are programmable, meaning that they can be configured to run a variety of different programs and operations, mostly in manufacturing plants. It can also be used to automate the different processes of the plant. 

Here are a few reasons why you should use a PLC Controller in your manufacturing plant:

High-Speed Control

PLCs can run at a very high speed, up to 100,000 instructions per second. This means that they can be used to control the different processes of a plant, like the process of filling a tank, in real time. This can be useful for any industry that has high-speed production. 

Robust

PLCs are very robust, meaning that they are able to handle a lot of load and stress.

Consequently, they are often used in industries that have a lot of moving parts, meaning they can keep up with even the busiest of plants. This makes them an excellent choice for any plant that has a lot of moving parts, but not enough manpower to fill it. 

Easy to Operate

PLCs are easy to use for the most part. You can use a variety of different programming languages to program them, but hiring a professional PLC Programmer such as RL Consulting can make that process easier. This makes them an excellent choice for any plant that requires a lot of programming, or is looking to take some of the man’s work out. 

Flexible

PLCs are flexible, meaning that they can be configured to handle a wide variety of different applications and tasks. They can be used in many different industries, including utilities, manufacturing, and agriculture. 

High Accuracy

PLCs are also very accurate. They are programmed to run different tasks, so they can be used to automate the different processes of a plant, and keep track of the progress of the tasks. This makes them an excellent choice for any plant that needs help to keep track of a lot of data. They are even more accurate than humans. 

Manageable Maintenance

PLCs are easier to maintain than you might think. They can be used to automate the different processes of a plant, so they can run automatically, without having to be manned by an employee. If you do need maintenance or have any issues with your PLC, reach out to an Integration Controls company, or the maker of the controller itself.

RL Consulting Inc. is a controls integration company specializing in PLC Programming, integration and more. If you would like to talk more about programming your PLC, contact us today. 

When building an automation system, it is important to choose the right system integrator to get the job done right. The right integrator can help you streamline your workflow, integrate your automation system with your company’s other systems, and take the guesswork out of the equation. Automation systems are an essential component of any modern manufacturing facility. The way in which they are designed and implemented can greatly affect the efficiency of the manufacturing process. It is therefore important that the correct system integrator is chosen. 

When choosing a system integrator, there are several things to consider, including:

Experience

Integration experience is important, because you don’t want to work with someone who doesn’t know what they’re doing. However, experience alone is not enough. The person you choose should be someone who has a proven track record of delivering.

Quality

Quality is a big deal when it comes to system integration. You want to work with someone who is going to deliver on time and on budget. A good integrator should be able to deliver on both of these fronts. A good way of knowing the quality of work they provide, is to read their reviews from previous clients. If there are multiple negative reviews, then you might want to look elsewhere. 

Cost

When choosing a system integrator, you want to make sure that you get a fair price. You should be able to negotiate with the integrator, and they should be able to give you a detailed breakdown of the costs for the services they are providing.

Knowledge

Finally, it is important to know that they have the knowledge and expertise to work with your specific requirements. A good integrator should be able to understand your goals, and provide a plan that will get you where you want to be.

The following steps will help you find the right controls system integrator for your company:

Define your requirements

First and foremost, you need to define your requirements. This includes the type of automation you are looking for, as well as the number of systems you want to integrate.

Nevertheless, you also need to consider how the automation will be used, and what its end use will be. For example, if you are looking to integrate an automation system that is designed to operate at a single location, then you may want to look at a centralized automation system. If you are looking for a system that will be deployed across multiple locations, then you may want to look at a distributed automation system.

Identify your needs

Once you have defined your requirements, it is important to determine what needs to be integrated and what your overall goal is. 

For example, if you are looking to integrate a production line with a new automated welding system, you will need to make sure that the new welding system is compatible with your existing production line. You will also need to identify how the automation system will be used. If you want to automate the welding process or other processes, then you will need to determine whether the automation system will be designed to run in the welding cell or in the cell next door.

RL Consulting Inc. can help with your next automation project. Contact us today for a quote.

Control automation integrators are specialists in the field of automation. They work with  manufacturers and contractors to integrate control automation solutions into their operations. In  this post, we’ll cover what control automation integrators do and how they do it.  

What does a control automation integrator do?  

A variety of industries use control automation integrators, and it can be challenging to determine  which one will best suit your needs. While there are many, they all have one thing in common:  they’re able to integrate and automate control systems to allow for safer, more efficient, and  better-quality processes.  

The automation integrator’s job is to set up and operate the control system. This includes  programming the controls and wiring them to the sensors and other equipment.  

The control automation industry is one of the fastest growing and most exciting sectors of the  electrical engineering industry.  

In recent years, automation has gone from being a novelty to a reality in many industries, and  the control automation integrator (CAI) is at the heart of the automation revolution.  

What is a control automation integrator?  

A CAI is a company that specializes in the design, installation and integration of control  automation systems. Hence, they’re called control automation integrators. A CAI is the main  provider of automation technology, including control systems and equipment. They work with a  variety of industries to design and implement control automation solutions. These industries  typically include manufacturing and distribution, such as food and beverage, pharmaceuticals,  and logistics.  

What is an industrial automation system?  

An industrial automation system is an integrated system of equipment, software, and processes  that allows for the automated control of production processes. This can include the automated  operation of machines, the monitoring of production processes, and the automation of  manufacturing and business processes. Industrial automation systems are built to perform a  specific task or function. They can be used for anything from controlling the speed of a  production line to monitoring and controlling the heating of a warehouse.  

While automation and control systems are similar, automation is more specific. An automation  integrator is able to integrate control automation systems. 

What is a control automation system?  

A control automation system is a system that controls a process. A process can be any process,  such as a manufacturing process or an operation in a production line.  

A control automation system can include the following:  

• Control systems  
• Sensors  
• Electrical control panels  
• Communication systems  

A control automation system consists of four main components:  

Control system  

The control system is the core of the automation system. It’s where the programming and  automation takes place. The control system is the brain of the automation system. And then the  brain communicates with the other parts of the automation system.  

Sensors  

Sensors are the eyes and ears of the control automation system. They monitor the process and  transmit information to the control system. Sensors are the main part of the control automation  system.  

Electrical control panels  

Electrical control panels are the face of the control automation system. They control the process  and receive information from the sensors.  

Communication systems  

Communication systems allow for the transmission of information between the control  automation system and the other components.  

If you are looking for an experienced control systems integrator company, contact RL  Consulting, Inc. today!

The first PLC’s were built in 1968 by Japan’s TOSHIBA corporation under commission from I.B.M. The PLC was then known as I/O Automation System or popularly known in Japan as the Q-series, mostly because of its letter designation in I.B.M. ‘s product naming convention.

Programming these early PLC’s were only made available through systems manufactured by third parties or via assembler code programming on custom made PLC’s.

In 1972, I.B.M. released its first ever PLC, called the 1800 series PLC, which was programmed using ladder logic, a graphical language of interconnected rungs or contacts and coils or ladders that visually represented relay logic systems. Ladder logic uses single-line symbols to represent the various components in a PLC system.

In 1980, I.B.M. released its second generation PLC, called the 4-series or more famously known as the Series/1 PLC which was built with both 24 bit and 32 bit processors with 5 to 15 input/output units with programmable functions for control applications and supporting a large range of third party products and programming tools.

Programming of these PLC’s were made available through assembler code programming, making the 4-series PLC the first ever to be programmed using assembly language. At this point of time, I.B.M was challenged by number of companies such as Rockwell Automation, Allen-Bradley, Mitsubishi Electric Corporation with their MELSEC PLC series and General electric.

Approximately three years later, in 1983 I.B.M made its first attempt to branch away from being the only one offering programming languages for their PLCs by making available their first third-party programming tool called the I.B.M PLC Editor/2, which was a dedicated programming language for their 4-series PLCs only. But due to lack of market demands and competition from third party manufacturers offering much cheaper alternatives, this dedicated programming software was not able to sustain the prices that I.B.M had placed on it and was soon discontinued.

In 1984 I.B.M made its second attempt to offer programming for their PLCs, by further developing assembly code programming language and also made available a new dedicated programming software called the Micro Logic Control Development System. But due to the same reason of it being too costly and not able to compete with other cheaper alternatives, sales were poor and I.B.M eventually abandoned this tool in favor for third-party programming tools developed by various companies such as Faun Elektrik, PASCO Scientific & Mechatronic Systems, Rockwell Software & Automation Solutions and many others offering much cheaper alternatives with no strings attached unlike the dedicated development software from I.B.M.

In 1985 I.B.M released its third generation PLC, called the 6-series PLC which is compatible with Series 1 & 4 PLC’s programming language and also offered an offline version of it called Programmable Logic Controller Studio/1 for easy portability to multiple platforms or even on-site user sessions. Programming of these PLC’s were made available through third party programming tools such as the I.B.M. Micro Logic Development System (PLD), which was also offered in an online version called the I.B.M PLD/1 and later improved upon to support multiple languages including function block, sequential function chart, ladder logic & structured text and many others.

In 1989 I.B.M offered its fourth generation PLC, called the 7-series or more famously known as the S/7 which is compatible with Series 1 & 4 PLC’s programming language and also offered an offline version of it called Programmable Logic Controller Studio/1 for easy portability to multiple platforms or even on-site user sessions. Programming of these PLC’s were made available through third party programming tools such as I.B.M Micro Logic Development System (PLD), which was also offered in online versions called the I.B.M PLD/1 and later improved upon to support multiple languages including function block, sequential function chart, ladder logic & structured text and many others.

While this only covers a short summary of the history of PLC Programming, there is a lot more to learn and understand about the history and future of PLCs. If you’re looking for a PLC Programming company, contact RL Consulting Inc. today!

PLCs (Programmable Logic Controllers) are very small industrial computers. They have modular components that are specifically designed to take customized control processes and automate them. Industrial plants and factories are where PLC programming is most commonly needed to control different motors, pumps, valves, breakers and more. 

Let’s take a deeper look into Programmable Logic Controllers and PLC Programming. 

History of PLCs

The first programmable logic controller came along in 1968 and replaced complicated electromechanical relay circuits that were used in the early to mid 1900s in industrial plants. Engineers and technicians found the PLCs easier to navigate, program, and use. 

Before PLCs were introduced, those complicated electromechanical relay circuits were used for automation in factories. The problem? It could take thousands of relays to automate a simple factory process. Which means if one thing needed to be changed in the circuit, it wouldn’t be a simple task. 

The first PLCs introduced had limitations when it came to speed and memory, however they were quickly improved over the years. PLCs really helped set the stage for industrial automation and helped it become what it is today. 

How Do PLCs Work?

PLCs are strong and complex computers and although there are many different components to PLCs, there are three important parts that operate together – CPU (Processor), Inputs, and Outputs. The CPU is what makes the desired action occur. The Inputs and Outputs are kind of like signals that relay information to the CPU and tell it what to do. Here is a step by step of the process:

1. The CPU monitors the Inputs (Valve 50% open, turn on switch etc.)
2. The CPU takes information from the Inputs and performs action. 
3. The CPU then operates the logic from the outputs. (turn off motor etc.)

Inputs and Outputs can be a variety of different actions such as turn sensors on/off, open/close valves, turn switches on/off, activate heating elements and so much more. And when you need to make a change, they can be easily reprogrammed to fit new processes. 

RL Consulting is Your PLC Programming Integrators

We are an expert electrical control design company specializing in PLC Programming and Control Systems Integration. With almost two decades of experience in the control design industry, we can develop new control systems entirely, or add to pre-existing systems. We can help talk through your goals and deliver a solution in a timely and professional manner that you will be pleased with. 

For more information, contact RL Consulting here.