First and foremost, RL Consulting Inc. is an engineering and technical consulting firm based in Muscle Shoals, North Alabama. We cater to clients close to home and all across the country, helping them tackle complex projects involving electrical controls design, project management, and more.

But we’re also a certified Silver System Integrator of Allen-Bradley products from Rockwell Automation. What does that mean? It means we’re more than just an Allen-Bradley provider or vendor; we’re a tried-and-tested partner with specialized know-how in control systems, low-voltage drives, and machine safety. Although we don’t offer tech support on behalf of Rockwell over the phone, our certified status enables us to bring you top-notch solutions using and maintaining Rockwell’s automation products.

What’s the Relationship Between Allen-Bradley and Rockwell?

Allen-Bradley, founded in 1903, set the standard for quality in automation and controls. Rockwell acquired Allen-Bradley in 1985 for a whopping $1.651 billion. This merger combined Allen-Bradley’s expertise in control systems with Rockwell’s diverse capabilities in other sectors like aerospace and automotive. The name change to Rockwell Automation took place in 2001, aiming to unify the brand. You’ll still see Allen-Bradley on products, but they’re now part of the broader Rockwell brand.

How Rockwell/Allen-Bradley Integrator Partnerships Work

So that makes Allen-Bradley a product line under the umbrella of Rockwell Automation, focusing primarily on automation and control products. It’s not a minor player; we’re talking about a brand with an estimated $4.2 billion in annual sales. The company has a global footprint, boasting over 70 manufacturing facilities worldwide. Allen-Bradley operates across three major segments: instrumentation, control and measurement, and systems.

What an Allen-Bradley Integrator Does

If you’ve ever heard of an “Allen-Bradley system integrator,” that’s us! RL Consulting is a certified company that creates and sets up Rockwell Automation and/or Allen-Bradley systems. We’re a third-party partner, collaborating directly with Rockwell Automation to help design, install, and maintain your Allen-Bradley control systems. We handle everything from small to large-scale projects.

Allen-Bradley Certification and Training are Non-Negotiable

At RL Consulting, we take our partner role seriously. To be an Allen-Bradley system integrator, you must have a valid Certificate of Registration from Rockwell Automation. This isn’t a one-time thing; we renew the certificate annually under the supervision of a qualified Rockwell sales representative. We also commit to ongoing education. Each year, we complete a minimum of six hours of Allen-Bradley-specific training. Additional training might come up, and we’re on it. Rest assured, we’re compliant with all federal, Alabama state, and local laws, which includes meeting NEC and ANSI standards.

Benefits of Being a System Integrator Partner with Rockwell

Our close relationship with Rockwell Automation means several things for you as our client. We have an insider’s view into Rockwell’s offerings, keeping us updated on product changes. The partnership also lets us plan strategically, knowing what innovations or updates Rockwell will likely introduce. Since we’re a certified system integrator, our services come with a Rockwell endorsement, giving us an edge over many competitors. Our relationship also opens doors for us to co-create new features with Rockwell, which can benefit our clients.

Other Valued Partners  of RL Consulting Inc.

Teaming Up with GE Fanuc

We’re also an alliance partner with GE Fanuc. This partnership came into being after extensive technical, operational, and quality evaluations. Our collaboration with GE Fanuc underlines our commitment to delivering solutions with proven skill sets and complementary technology application expertise.

Connection with InSource

We work closely with InSource, a leading provider of manufactured intelligence services and software and hardware solutions. The main aim here is operational synergy, especially in manufacturing environments.

InduSoft for Versatile Applications

InduSoft is another partner we rely on. They offer potent HMI and SCADA software solutions applicable in various sectors like building automation, detention systems, oil and gas, and water treatment.

Achieving Manufacturing Goals with Omron

Omron is a specialist in control components and systems aimed at factory automation. They help companies achieve their manufacturing objectives. As a partner, we bring Omron’s extensive capabilities into our service offerings.

Strategic Partner with Siemens

Siemens is a global technology powerhouse specializing in decentralized energy systems and intelligent infrastructure. Their focus also lies in automation and digitalization in the processing and manufacturing industries, making them an integral part of our service ecosystem.

Partnering with SMC for Automatic Control Equipment

SMC specializes in manufacturing, processing, and selling automatic control equipment. We can incorporate SMC’s state-of-the-art technology into our projects, enhancing the solutions we offer you.

Each of the companies we partner with adds unique value to our services. It’s not just about what we can do; it’s about what we can do together to make your next automation project a triumph.

We Want to Be Your Trusted Automation Partner

So why does all of this matter? When you work with us, you’re not just hiring a company; you’re teaming up with a partner already trusted by global companies in electrical control systems and automation. So, whether it’s a Rockwell automation system or a GE Fanuc operation you’re interested in, you can count on RL Consulting Inc. to bring a certified level of expertise to your project, along with a high degree of skill and care.

Feel free to contact us to learn more about how we can make your next automation project come to life.

If you run a factory, a warehouse, a manufacturing plant, or even just a building with an HVAC system, partnering with an industrial automation provider like RL Consulting can supercharge your operations. 

Here’s how.

The Main Benefits Of Integrated Industrial Automation

Systems integration specialists work with you to assess your needs, then they design and implement time- and effort-saving automated solutions for your work processes. 

Activities like welding, painting, packing, drilling, delivery, and assembly are just a few examples of things your business can do better, faster, and more safely with integrated systems automation.

And the results?

• Increased productivity 
• Greater efficiency
• A safer work environment

Companies that do manufacturing, packaging, or storage are well-positioned to achieve these outcomes. Yours could be too. 

That’s why we’ve put together this guide to the types of businesses that should be thinking seriously about process automation in 2023.

But first: Here’s a quick refresh on what industrial automation integration is and how we do it at RL Consulting. 

What Do Automation Integrators Do?

As an automation provider, we use programmable logic controllers (PLCs) to take over your work processes, installations, or equipment and automate them, so that they do what they’ve always done (if that’s what you want!) — only better. 

What Are Programmable Logic Controllers?

PLCs are small industrial computers — think of them as the brains of your factory or building. 

A good systems integrator company can hook these brains up to any automated processes you already have and enhance them. Or they can design and install new systems from scratch. 

At RL Consulting, we offer both these services, as well as

• End-to-end project management
• Training on new systems for your employees
• Ongoing maintenance and support 

So, Could An Industrial Automation Consultant Help Your Business?

If your success depends on things like pumps, motors, valves, breakers, conveyor belts, cranes, storage systems, HVAC systems, or elevators, then a control systems integrator can help you future-proof it. 

In the 20 years since RL Consulting was established, our programmable automation expertise has made significant wins for clients in the following sectors:

• Food and beverage (oil refining, pet food) 
• Pulp and paper (tissue, paper, and board)
• Pharmaceuticals (packaging for pills and liquid medicines)
• Metal (steel and aluminum)
• Rubber (mixing, hoses, and extrusions)

And there are countless other applications too. For example, in the automotive and construction industries, aerospace and defense, transportation and logistics, energy and utilities, and even in hospitals.

Choosing an Industrial Automation Integrator  

Finding and hiring the right manufacturing automation provider helps you ready your operations for whatever’s coming next, while protecting your employees. 

It’s an investment in productivity and efficiency that ultimately protects your bottom line, because you get to do more of what you do best and you get to do it faster, with fewer manual interventions.Your employees also have less physical contact with high-risk equipment and processes.

We’d appreciate the opportunity to learn about your business and help you decide if we’re the right automation integrator for you. Contact us at RL Consulting today.

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.