Customer Background
A powerhouse in industrial solutions, this Japan-headquartered company specialises in a comprehensive range of products including motors, control systems, drives, motors, and automation systems for industrial applications. Their expertise in renewable energy, oil & gas, metals, material handling, mining, and other critical industrial markets, combined with a strong commitment to innovation and sustainability, has driven their global success.
Customer Need
To enhance long-term viability, reduce operational costs, and integrate Industry 4.0 technology, our customer sought to modernise their entire portfolio of automation and control systems for hot rolling mills. Additionally, they needed a reliable partner to support the commissioning of hot strip mills for their global clientele. Based on our successful, long-standing partnership across multiple projects, Softdel’s comprehensive chip-to-cloud expertise and industrial domain knowledge, the customer collaborated with us on this critical industrial process automation initiative.
Softdel’s Solution
- As an Engineering and R&D technology partner, Softdel assessed the project scope and implemented a streamlined, multi-level approach; this structured upgrade encompassed every aspect from control system design to testing and commissioning.
- Softdel developed the system architecture and hardware schematics for the control panel, which included:
- Renewal of existing system configurations, with updated system architecture and topology.
- Updated schematics for PLCs, Remote I/O (RIO), and drive panels.
- Detailed designs for the control system, electrical panel, and changeover panel.
- In PLC programming, we covered modernising the customer's PLCs to meet functional requirements:
- Hardware and input / output drive registration, including parameter settings and communication interfaces.
- PLC programming using Ladder Logic, function block diagram, and sequential function charts along with HMI and other PLC interfaces.
- Transmission speed & scan calculations for system design and network operations.
- Integration of third-party systems via various industrial communication protocols.
- To support the customer’s Industry 4.0 transformation, Softdel migrated the desktop-bound HMI to a web-based SCADA, providing remote monitoring and control with an intuitive user-friendly dashboard featuring PLC status, alarms, historical signals, and ODG recordings.
- Upon completing the Hot Strip Plant automation, Softdel conducted rigorous testing and assisted in the installation and commissioning of the down coiler system, encompassing:
- System and Interface Testing: I/O and sensor checks, third-party interface tests, as well as manual and automatic movement validations.
- Functional and Reliability Testing: Manual and HMI tests, individual and combined auto function tests at various levels, cold run mode tests, and rolling mode tests.
- Safety and Operational Testing: Emergency and safety systems checks, interlock tests with site machines, cold run tests without materials, and final rolling and tuning.
- Performance Monitoring and Reporting: System performance recording test results and creation of Factory Acceptance Test (FAT) reports.
- Site Acceptance and Handover: Site acceptance tests, performance guarantee documentation, and site handover reports.
Standards and Technology
Tools: PLC Programming-Engineering, Visio Based Schematics/Hardware Design, HMI & SCADA Engineering
Communication Protocols: TC Net, TCP/IP, Profibus
Programming Language: IEC 61131-3 international standard for PLC programming
Benefits
- AI-ready Industry 4.0 integration: Softdel’s expertise in intelligent process automation and advanced capabilities for seamless web-based communication enabled real-time data access, remote monitoring, control, and optimised system operations.
- Optimised performance and cost efficiency: Real-time monitoring and predictive maintenance reduced downtime and boosted cost efficiency by 30% while minimising inventory requirements through just-in-time production.
- Enhanced product quality: The customer rapidly achieved product grade quality, minimising production time while maintaining high standards.
- Improved troubleshooting and maintenance: This advanced automation enhanced troubleshooting capabilities and facilitated early fault detection and resolution, reducing maintenance time.
