Automation
- Automation has revolutionized and continues to improve every area of application.
- The integration of transducers, input feedback signals, processors, power supplies, human machine interfaces and output Signals, with effective software at different levels, ensures that steps of the process are executed in a predetermined, predictable and optimized manner meeting process and machine requirements.
- Integration of plant data over cloud and remote monitoring with predictive management support in line with IOT 4.0
- Controls offered range from the Simple standalone to complex controls involving Fault Tolerant CPUs in redundant hot standby configuration with high levels of monitoring and integration with higher level systems and large amounts of secured data exchange.
- Appropriate sizing and application of complex Motion Controls with fast response times, and complete spectrum of variable speed drive applications
System Integration Strengths
- Range of controls offered is biased to more complex projects with large number of inputs and outputs, redundancy, fail safe applications, advanced Scada features, OPC connectivity, large and redundant communication networks while keeping the operation of the system simple and intuitive to use.
- Good understanding of system dynamics help us arrive at the optimum solutions for critical time dependent and synchronous operations through prime movers.
- Attention is paid to power system fault levels, graded protection and critical standby systems.
- Excellent documentation and training to end users, and adherence to international standards in design and manufacture ensures years of trouble free operation.
- We are ISO 9001-2015 certified company. Our systems compliant to UL508A (Certifcate No.20190313-E350288) for USA & Canada and CE (Safety and EMC compliance) for Europe.
Autodata has experience working with SIEMENS, ABB, Rockwell Automation, PLCs, enabling I/O optimization. Our solutions are exceptional due to close cooperation with the clients and understanding what is of the maximum value for them. Our automation expertise spans major manufacturing industries, Automobile, Chemical processing, Pharmaceutical, Steel, Power, Nuclear and Utilities. Autodata has the automation experience and expertise needed to optimize the investment in your control systems. Leverage our vast automation experience to gain a competitive advantage, realizing executable solutions for all your challenges.
We continue to grow our team by actively recruiting and training resources on SIEMENS platforms, such as SIMATIC PCS 7, SIMATIC S7-200/300/300R/400/400F/H and TIA portal S7-1200/ 1500/1500R/H, WinCC as well as the legacy S5 Series platform.
We also offer complete variable frequency drive and servo systems (SIEMENS S120, G120 and ABB ACS 5xx/8xx) & commissioning.
Our team has a more comprehensive, deeper understanding of CPU Redundancy, IO Redundancy, SCADA interface to Plant DCS redundancies, SCADA Redundancy, Fail safe configurations to SIL2, SIL3 (1001) and (1002) configurations.
Automation solutions in Hazardous Areas like Zone-1 and 2
Vast Experience in configuration and implementation of Field bus protocols like Profibus, Profinet, Modbus, Modbus TCP/IP, Ethernet IP, Control net, Canopen.
We continue to grow our team by actively recruiting and training resources on SIEMENS platforms, such as SIMATIC PCS 7, SIMATIC S7-200/300/300R/400/400F/H and TIA portal S7-1200/ 1500/1500R/H, WinCC as well as the legacy S5 Series platform.
We also offer complete variable frequency drive and servo systems (SIEMENS S120, G120 and ABB ACS 5xx/8xx) & commissioning.
Our team has a more comprehensive, deeper understanding of CPU Redundancy, IO Redundancy, SCADA interface to Plant DCS redundancies, SCADA Redundancy, Fail safe configurations to SIL2, SIL3 (1001) and (1002) configurations.
Automation solutions in Hazardous Areas like Zone-1 and 2
Vast Experience in configuration and implementation of Field bus protocols like Profibus, Profinet, Modbus, Modbus TCP/IP, Ethernet IP, Control net, Canopen.
Programming and configuration brings to life the detailed design of the instrumentation and control system that is developed in cooperation with the client and appreciating how to ensure maximum value for the life of the equipment. Autodata control engineers have extensive experience working with PLC systems. They apply this automation knowledge in using the latest engineering tools to convert P&ID diagrams and control philosophy to the required PLC software characterized by the use of standard generic and custom function blocks specific to the application.
With the features available in modern control systems, even complex advanced control strategies can be configured and programmed in these systems. Autodata provides design of integrated control system from field I/O's to MES systems.
With the features available in modern control systems, even complex advanced control strategies can be configured and programmed in these systems. Autodata provides design of integrated control system from field I/O's to MES systems.
Autodata project execution methodology is the basis for our systems development and service offering. This applied methodology ensures that our team follows good engineering practices during all phases of development, During all phases of the project starting with the kick off meetings to the final commissioning and hand over. This includes the control philosophy, HMI and SCADA programming and configuration; historian configuration and database programming and documented testing. All phases of software development are subject to revision control and documentation. Our breadth of automation services allows us to provide comprehensive implementation of our engineered solutions, including technical services to support the control system installation, commissioning and start-up and post-start-up support.
HMI solutions we understand the need to apply newer guidelines for safety and efficiency while maintaining an interface that’s comfortable and effective for your team. We develop graphics utilizing the latest layering concepts, optimized for multi screen environment. Our software design teams work with you to meet your goals, and our experience and size allow us to offer competitive pricing.
When your facility undergoes a planned or unplanned shutdown, scheduled downturn or turnaround, you may have to complete a large range of maintenance tasks in a limited time period.
Plants across a wide range of industries look to Autodata to provide additional staff support, maintenance expertise and the parts needed for these shutdowns. As part of our Field Services offering, we provide shutdown planning and services. Depend on us for the services, expertise and resources you need before, during and after an shutdown, helping you get back up and running on schedule.
Plants across a wide range of industries look to Autodata to provide additional staff support, maintenance expertise and the parts needed for these shutdowns. As part of our Field Services offering, we provide shutdown planning and services. Depend on us for the services, expertise and resources you need before, during and after an shutdown, helping you get back up and running on schedule.
We have executed a number of projects in the following fields:
| Automobile | Paint shops, Test Beds for R&D and Production Lines, Rectifiers and Automation for CED. |
|---|---|
| Chemical | Sulphur Melting and Filtration, Chlorine Compressors, Batching plants. |
| Furnaces | Ship Loader/Unloader, Engine monitoring systems. |
| Nuclear | Waste recycling and disposal systems, Fuel bundle handling and inspection stations, Cobalt 60 Irradiation Plants for Pharma and Food. | Pharmaceuticals | High Speed Centrifuge controls, HMI solutions in Life science applications. Humidity control with our heater controls. |
| Plastics | Blow moulding, Injection Moulding, Pre-form machines, Pipe Cutters, Pipe making . | Shipping | Ship Loader/Unloader with associated material handling, Engine monitoring systems. |
| SPM | Press brakes, Material handling, Tube cutting, Electron Beam welding power supplies. |
| Steel & Non Ferrous | Strip Processing lines like CGL, tension levelling, pickling, slitting, cut to length, continuous casting, Thin strip mills. Range of furnaces like Bell Furnaces, reheating, walking beam and hearth, hardening and tempering, homogenizing |
| Tyre | Rubberizing Process Lines. | Wire and Cable | High Speed Insulating lines for Building wire, Fine Wire Drawing, Rod Breakdown, Drum Twisters, Stranding machines, coiling, extrusion lines, braiding, CV lines. |
| Water | Storage and Distribution, RO and UV plants. |
Furnaces
- A bulk of these furnaces are used in the heat treatment of metals as in Roller and bogie hearth, bell Annealing, walking beam, Continuous galvanizing line furnace, Annealing and hardening furnace Continuous and batch processes.
- Furnaces can be oil, gas or Electric heated.
- Automation of these furnaces take into account the safety of operation, fuel/air ratio, burner management, zone wise cascaded temperature control, calculation based on heat flow and loss, thermal inertias, induced and forced draft blower control, recipe control of the temperature profile with respect to position and time, Optimization of throughput, reducing the heat loss during charge changes, recording performance and costs of operation, record of heat treatment processes, history, consolidation of multiple furnace outputs, and intimation of maintenance requirements, and connectivity to the cloud.
- Other aspects of control refer to the charging and discharging station control. There are also extensive programs for the tracking of the billets, coils, bundles as they are processed through the furnace, with a recording of the process they are subject to and to estimate when the output will be available for further processing such as rolling mills.
Automobile Factories > Paint Shop and conveyor Systems
Automation Systems for an Automobile paint shop in the manufacturing line involves the control of various sub sections such as:
Pretreatment both conveyors based with sprays and tanks with a suitable transporter system in which the components are chemically cleaned before painting. While the conveyor based systems are generally meant for small components, the larger components are usually treated in a variety of tanks. The controls optimizes the movement of material through the various tanks to ensure good cleaning in minimum time.
CED Rectifier Primer coating. This control is supplied with a suitable DC supply based on IGBT technology for minimum ripple and high power factor and efficiency with low harmonics. These units are made suitable for both live entry and dead entry of parts to be painted. Interface with the plant DCS is provided to coordinate with the main production program. The controls ensure the synchronization with the input conveyors and allow for suitable recirculation with the recovery of the undeposited paint is passed through an ultra filtration unit and reused. This control is crucial, as this is one of the units that determines the entire plant capacity.
The subsequent ovens and burners ensure the curing of the paint makes for a hard and durable polymeric film as a primer base. After the final paint in the final Booth that is usually managed by robots, the chassis or parts are again heated in ovens. Mostly IR Heaters are used with Thyristor control for maintaining the temperature required within close limits.
Scrubbers and sludge removal systems entrap the loose paint particles with a controlled air and water flow in the under section of the booth and transports this to the paint mix station. Water is recirculated after suitable filtration.
Conveyors of various types such as Power and Free, Power pulled and roller beds are used. They have to be synchronized with the rest of the operation. Especially important is when transfer has to be done from one conveyor to another without stopping the line. Special controls have been developed for the transfer of chassis while in motion from one conveyor to another.
Hoists, Scissor lifts, AGV and turntables are used frequently to reduce the plant foot print. Controls stress on the safety and synchronous operation with the rest of the conveyor system.
Storage solutions ( Carousel, lift storage etc) need to ensure systems for dense storage with fast recovery of specific components.
RFID ( wireless) identification of parts is done to track the position and help in fast recovery of the particular component in the flexible manufacturing systems.
Machine shop supervision includes Manufacturing Execution Systems that integrate with plant ERP systems (through predefined data base exchanges) to obtain real time data from the shop floor.
Automobiles > Testbeds
Chassis dynamometer
Typically used to test the performance of vehicle, exhaust emission , fuel consumption, noise and fine tuning of exhaust and catalyst and motor fuel-injection system. Dynamometers simulate the real highway/ road driving conditions precisely. This requires that during acceleration and deceleration, the roll inertia be compensated dynamically , to match the mass of the tested vehicle and the real road. To be able to realize such high dynamic online compensation, the load torque of the roll motor is controlled accurately and with extreme precision at every speed point.Chassis dynamometer for two wheelers , three wheelers , four wheelers delivered.
Engine test stands
To measure power and torque directly from the engines crankshaft means knowhow in the selection of a correct AC machine with proper electrical and mechanical characteristics like smaller leakage inductance and inertia , and fast torque response management are challenges we are aware off and successfully delivered high performance test stands . Torque rise times achieved 1-2millisecs. On the fly bump-less switch between Speed/Torque , Torque/Speed. Up-to 10000 RPM Max speeds
Transmission and clutch Test Stands
These stands include several motors — one simulating engine, and two or more to simulate the road. This requires mutual coordination of drives operation, the faster and more accurate it is the better it simulates real-world conditions like differential gear operation. Uphill/Downhill drive modes . Up-to 10000 RPM Max speeds
Atomic Energy-Gamma irradiation plant controls
A number of times in close coordination with the OEMs and the Atomic Energy Regulatory Board. Incorporation of very high levels of safety, 21CFR US FDA compliance.
- Gamma irradiation plant controls for the irradiation of medical products, agriculture produce such as Onions and mangoes, surgical gloves and accessories, necessities, with the attendant safety, material transport and ensuring the elimination of pathogens have been done
- ADFTS Automatic Direct Bundle transfer system
- Pellet inspection systems
- PHWR Special purpose automatic energy bundle inspection system
- Special programmed ovens
- Glass heating systems for encasing for atomic waste disposal units.
- Transport systems for Container Inspection systems
Wire and Cable Machinery Control
Controls for a range of machinery from Rod Break down, Intermediate wire drawing, fine wire drawing, In line annealing, Insulation lines, Extrusion lines for cables, Bunching and stranding machines, Vulcanising lines, High voltage cable lines, Mixers, pay off and take up winders, These lines involved coordinated variable speed drives. Temperature control and heater control, sequence logic and safety systems, diameter sensors, speed correction algorithms
Strip Processing Lines
Steel and non ferrous strips slitting, cut to length, leveling, tension leveling, accumulators, bridle rolls, un coilers, coilers, weld detection. Automatic change over of pay off coils. Forming mills that process strips and form them into the required shapes in successive stands need coordinated drive systems and dancer control. These controls include welding rod production units with material filling, card clothing side strips etc. Complete paper and board plants, slitting lines, flying shear cut to length lines.
