Category Archives: Case Studies

Cloud-based data dashboards

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If you want to see how your machine or process is operating day in day out from anywhere in the world, where do you start? With the increased risk of hacking of industrial devices becoming ever more prevalent Security Week – New Vulnerabilities Can Allow Hackers to Remotely Crash Siemens PLCs it’s not as simple as just hooking your PLC onto your local network.

An increasing number of companies are turning to remote cloud-based solutions for machine monitoring. Optima are pleased to offer the Cloud-based solution which keeps your automation hardware safely behind a secure firewall. Most of our clients prefer a SIM-card based system. The benefits of this system are that the equipment is always live whenever there is cellular reception available. Our range of antenna options mean that reception is possible even in the most remote locations.

The video below shows a basic demonstration dashboard. If you would like to know more then please get in touch – we like to talk!

This video gives a very brief demonstration on how our Remote Access and Cloud Logging System can help you keep track of how your machine is performing. See when the machine is started, stopped, realise production metric data straight to your mobile, desktop or tablet.

We have been trialling our remote machine data dashboards #iot #industry4. These allow real-time data to be visualised from any PLC anywhere in the world to a PC, tablet or mobile ‘phone anywhere in the world! The system can communicate over 4G, Wi-Fi, or a direct Ethernet connection. From Kazakhstan (yes, we do have two units out there!) to Kendal (we haven’t got one there yet…), we have you covered for a very low monthly cost.
Our remote reporting dashboards which can send #production #reports by #email will shortly be ready for release.

For more information, please contact info@optimacs.com

Mark Lane.

Siemens Transform Event

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Join Optima at the Siemens #Transform2022 Conference being held at the Manchester Central Convention Complex on 12th and 13th of July to explore how digitalisation of industry is being accelerated. For more information and to register for a complimentary space, see #Transform2022. Some of the key areas are:

  • Edge and Cloud Data computing for machine diagnostics
  • Improving plant operational efficiency and reducing energy consumption
  • Use of resilient forms of energyJoin Optima, your trusted Siemens Automation and Drives partner at this event. It is the largest event that Siemens have ever organised in the UK so it set to be an event that shouldn’t be missed!

Rockwell Extended Warranties

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If you have recently upgraded your machine or purchased Rockwell Automation hardware from Optima, a simple registration process can protect your investment.

The benefits for your business include:

Registration is easy. Simply scan the QR Code on your product packaging to get started or use our registration portal to add your products manually. Once your registration is processed, you may enjoy an extended warranty, easy access to your products’ documentation and updates on the product lifecycle status.

Just one way that Optima can help you get the most from our upgrade.

S88 Solution Solves Obsolescence Issue

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Addressing obsolescence is an issue facing many companies and failure to create a robust action plan can often lead to problems that not only affect the operation of a line or machine, but can also result in unfavourable issues that could have detrimental effects on quality levels and brands.

The dangers of obsolescence were identified early on at a leading British biscuit manufacturer in its mixing plant, where older hardware was not only showing its age in terms of performance and failures, but was also no longer part of a supported spares package. More information can be found here: Rockwell Automation Case Study

More information here:

Allen‑Bradley ControlLogix programmable automation controllers

EtherNet/IP device-level ring network topology

Batch servers

Rockwell Automation integrated-display computer running FactoryTalk View Site Edition (SE)

Rockwell Software FactoryTalk Batch software solution

Up to 5 Years Warranty as Standard on our Motor and Drive Upgrades with Siemens

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As a trusted Siemens Drive and Motion Partner, any machine upgrade that Optima engineer that uses Siemens Drives and Motors, Siemens will provide a 5 year warranty on the drive and 3 years on the motor/ motor gearbox Free of Charge. Optima can also extend this standard warranty further for you at preferential rates as a trusted partner of Siemens. See the below link for more information:

https://new.siemens.com/uk/en/products/drives/extended-warranty-packages.html

To be accepted as a Solution Partner of the “Drives & Motion” arm of Siemens, Optima must fulfill the following qualification criteria:

  • A proven track record of many years of experience in implementing projects in drive systems engineering using Siemens components
  • Qualified management our own projects, configuration and quality
  • Regular auditing of partner performance by Siemens Automation and Drives

Optima’s Robot Programming Services in Demand

Link

Optima don’t just supply our own turnkey Robot cell systems, we are also able to provide programming, consultancy and support. We are able to work with the following major robot manufacturers and have extensive experience on: ABB, Kuka, and Fanuc.

All of our previous robot projects are available on our dedicated YouTube channel. Here’s a few samples below:

https://www.youtube.com/watch?v=iTSaR84XyfA width=”186″ height=”105″

Optima achieve accreditation by Avetta for supplier competency

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Optima have been certified as an approved supplier to Schneider Electric and become part of the Avetta Consortium. Membership of Avetta is your guarantee of our quality, procedures and most important of all, safe working standards.

We look forward to working closely with Schneider Electric on upcoming major projects. This enhances our product and engineering services and complements our existing Siemens Automation and Motion Partner services.

Registration Certificate Avetta

 

Re-commencement of commissioning on major projects

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Critical process industry can’t stop, so Optima have been back commissioning on-site for some time now to support our customers.

For this major project, we have written the PLC and SCADA platform to control the whole process from start to finish. The application is written entirely in TIA Portal with a total of three WinCC SCADA platforms. We have used the latest cloud-based remote access technology so that most of the plant can now be commissioned remotely. Remote access using a combination of local Wi-Fi and High-Gain 4G antennas gives us a reliable and secure access to the PLC and SCADA system when it is required.

This project is just one of many that Optima play a key role in. Whether your application is large or small, we have a capable engineering team that are able to provide you with as much engineering resource as you require.

March 2021

All the support you need… when you need it

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Here at Optima we are always looking at ways at which we can better support our customers. If the problem can be identified remotely and and fixed without requiring a visit to site, then there are cost savings to be made, both in terms of engineering time saved and production downtime losses.
Of course, not every problem can be fixed remotely, but if a more detailed prognosis can be made in the first instance, then preparations for any site visit will be more focused on the problem area. Read our Remote Access Brochure for more information.

Cloud Remote Access

With this remote access system:

  • Our engineers use the same software they would use if they had travelled to the remote site. The customer does not need to purchase the specialist programming tools or laptop
  • The system uses the existing, broadband Internet connection on site, whether wired or wireless
  • If this is not available (for example at a remote operating plant or location) our 4G Mobile Data Sim configuration provides the communication link required. 
  • Depending on network coverage, the most appropriate mobile telephone network provider can be selected. Our range of high-gain antennas ensure that a reliable data link is always available
  • The system can be configured to send e-mail notifications, when machine faults / alerts occur

We would be pleased to provide you with a custom quotation for your remote access requirements.

Supply of Motor Generator Test Rigs to Blackpool & The Fylde College

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AC and DC Motor Test Rig 1

If you want to learn about Asynchronous and Synchronous AC machines, DC Motors, Generator and Motor principles it’s useful to be able to carry out practical work on them.

Step forward Optima who helped Blackpool & The Fylde College fulfil their requirements to have two new state-of-the art installed at their brand new training facility near Fleetwood

Challenges

There were a number of key challenges in the design. On Test Rig 1, the AC Motor would operate in two modes:

  • Prime mover, with the load being applied by the DC motor.
  • Generator mode with the DC motor driving the AC motor.
Synchronisation Meter

When acting as a generator, the AC motor would have to be synchronised to the mains supply before being “switched-in”. This is to simulate a real-world situation on-board ships where back-up generators may have to be manually switched-in.

Design

The panel design incorporated banana type sockets to facilitate the ease of connection of external measuring instruments such as power meters.

The panels incorporated a host of instrumentation to afford total visibility. These included:

  • Machine torque
  • DC Armature Current
  • DC Armature Voltage
  • Single Phase Mains Voltage L-N
  • Single Phase Alternator Current
  • Single Phase Alternator Voltage L-N
  • Alternator Excitation Current

Test Rig 2

Test Rig 2 incorporated the very latest Siemens PM250 Regenerative Power Module and a Soft Starter to the test rig AC Motor. The user has the option to switch between the two. A DC Motor acts either as a prime mover or generator giving ultimate flexibility in operation.

The incorporation of a regenerative AC solution brings the very latest in cutting-edge drive architecture to an educational establishment. There aren’t many drive manufacturers who can supply lower-power regenerative modules.

Overall, the test rig projects were a great success combining the College’s and Optima’s knowledge to product test rigs that will serve students well for many years to come.

Technology:

Videos:

See our Test Rigs in action here: