Srinijan Automation Solutions

Srinijan Automation Solutions
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Projects

#industrialautomation #plcprogramming #hornerocs #automationengineering #scada #modbustcp #rs232 #rs485 #manufacturing #industry40 #processautomation #industrialiot #traceability | Srinijan Automation SolutionsProject Spotlight | Oven Automation & Integration (2021) Looking back at one of the industrial automation projects I completed in 2021. Successfully Delivered – Multi-Oven Automation & Integration Project Proud to share the successful completion of a comprehensive Oven Automation & Integration project. Project Overview The system consists of two independent production lines, each equipped with 16 industrial ovens. Each line is controlled by a dedicated Horner XL Plus OCS, ensuring reliable and independent operation. Key Integrations ✅ Custom Manufacturing Software Integration (RS-232) Operators select the required part through the customer's desktop application. Start commands are transmitted directly to the Horner XL Plus OCS via RS-232. Any oven can be selected and started from the custom software. ✅ Biometric Authentication A biometric fingerprint device communicates with the XL Plus OCS through a dedicated RS-232 port. After receiving the start command, the system waits for operator fingerprint verification. The selected oven starts only after successful operator authentication, ensuring controlled and authorized machine operation. ✅ Temperature Controller Network Each oven is equipped with an individual temperature controller. All temperature controllers are integrated with the XL Plus OCS over an RS-485 communication network, enabling centralized monitoring and control. ✅ SCADA Monitoring Both production lines are connected to an AVEVA SCADA system (formerly Wonderware InTouch) using Modbus TCP/IP. A 55-inch monitoring display provides real-time visualization of: Oven status Temperature Process information Alarm status Production monitoring Project Objective The primary goal was to transform a manually operated oven system into a fully automated and integrated production solution by combining: Industrial automation Custom software integration Operator authentication Process traceability Production data logging Centralized SCADA monitoring This project significantly improves operational efficiency, enhances process traceability, strengthens operator accountability, and provides comprehensive production data for future analysis and quality improvement. #IndustrialAutomation #PLCProgramming #HornerOCS #AutomationEngineering #SCADA #ModbusTCP #RS232 #RS485 #Manufacturing #Industry40 #ProcessAutomation #IndustrialIoT #Traceability Horner Engineering India Private Limited Horner APG Canada Horner Automation & Solutions Group Muthukumar Marimuthu

#hornerocs #automation #plcprogramming #dietraceability #dielifecount #iolinkmaster #rftags #rfreader | Srinijan Automation SolutionsDie Traceability and Die Life Counter System using Horner XL7e OCS Project Overview Developed a Die Traceability and Die Life Counter System using the Horner XL7e OCS to ensure correct die identification, prevent unauthorized die usage, and monitor die life based on press cycle counts. Hardware Used Horner XL7e OCS IO-Link Master IO-Link RFID Reader RFID Tags Die Press Count Sensor (connected as a digital input through the IO-Link Master) System Operation The machine is designed to operate with 10 authorized dies only. The master records for all 10 die names are stored in the Horner XL7e OCS and can be configured or updated through the HMI. Whenever a die change occurs, the RFID reader reads the RFID tag attached to the mounted die. The OCS compares the detected die name with the master die records stored in the system. If the detected die is valid and matches one of the authorized die records, the machine is permitted to operate. If an unauthorized or incorrect die is detected, an alarm is generated and machine operation is inhibited until the correct die is installed. Die Life Monitoring During machine operation, the die press count sensor detects each press cycle. Every press cycle is counted and automatically accumulated against the corresponding die record. The accumulated press count is stored individually for each die, allowing independent life tracking. When the press count reaches the predefined maintenance or replacement limit, the system generates a warning or alarm indicating that the die requires servicing or replacement. This preventive maintenance approach helps avoid unexpected die failures, minimizes production downtime, and prevents damage to both the die and the machine. Key Features Automatic die identification using RFID. Verification of authorized dies before machine operation. Prevention of incorrect die installation. Individual press cycle counting for each die. Automatic die life monitoring. Preventive maintenance alerts based on configurable die life limits. HMI-based configuration and management of die master records. Improved production traceability, machine safety, and die maintenance management. Horner Engineering India Private Limited Horner Automation & Solutions Group Horner APG Canada Muthukumar Marimuthu #HornerOCS #Automation #PLCProgramming #Dietraceability #Dielifecount #IOLinkmaster #RFtags #RFReader

#hornerocs #automation #plc #pokeyoke #plcprogramming #barcodeverification #srinijanautomationsolutions | Srinijan Automation SolutionsIntroducing the Blue, Yellow & Red Lamp Barcode Verification System for automotive child parts. This innovative solution addresses the challenge of verifying lamp colors during the poka-yoke inspection and welding process. The system ensures that the correct lamp color is assembled according to the selected part variant. While the existing system can differentiate Red lamps from Blue and Yellow lamps based on current consumption, it struggles with the latter two due to their similar current characteristics. To overcome this limitation, we are implementing a barcode verification system. Here’s the proposed sequence: 1. Select the required part variant. 2. Connect the lamp to the lamp holder. 3. Verify the lamp connection using the existing 4–20 mA current monitoring system. 4. Scan the lamp barcode. 5. Compare the scanned barcode with the master barcode stored in the PLC for the selected part variant. 6. If the scanned barcode matches the required Blue, Yellow, or Red lamp, the process continues. 7. After successful lamp verification, the operator scans the final product barcode. 8. Once verified, the welding cycle is completed successfully. This solution guarantees the correct lamp installation for every part variant, prevents incorrect lamp assembly, and enhances the reliability of the poka-yoke system. Horner Engineering India Private Limited Horner Automation & Solutions Group Muthukumar Marimuthu #HornerOCS #Automation #PLC #Pokeyoke #PLCProgramming #Barcodeverification #Srinijanautomationsolutions

#hornerocs #automation #plcprogramming #hmi #plc #industrialautomation #srinijanautomationsolutions #scada #industrialsolutions #programming #wastewatertreatment #watertreatment #projects | Srinijan Automation SolutionsI have successfully completed the PLC logic and HMI graphics development for a Wastewater Treatment Plant automation project after nearly 20 days of engineering and development. Project highlights: • Control logic for 9–11 motors and 10–11 automated valves. • Integration of inlet and outlet flow meters via RS-485 communication. • Automatic report generation with CSV file storage on an SD card. • Data logging of critical process parameters based on customer requirements for monitoring and analysis. The project is currently awaiting on-site commissioning and system verification. Once commissioning is successfully completed, I will share a demonstration video of the complete system in operation. Horner Engineering India Private Limited Horner Automation & Solutions Group Horner APG Canada Muthukumar Marimuthu #HornerOCS #Automation #PLCProgramming #HMI #PLC #IndustrialAutomation #SrinijanAutomationSolutions #Scada #IndustrialSolutions #Programming #WasteWaterTreatment #WaterTreatment #Projects

#automation #hornerocs #barcodesystem #programming #plcprogramming #hornerautomation #xleocs | Srinijan Automation SolutionsPacking Barcode Verification System to Prevent Part Mix-Up A barcode-based packing verification system will be implemented to eliminate part mix-ups during the packing process. Each individual part is marked with a unique QR code containing the part identification. Before placing a part into the master carton, the operator must scan the QR code. The scanned part number is compared with the selected production part number. If the scanned QR code matches the selected part number, the system accepts the part and allows it to be packed. If the scanned QR code does not match, the system generates a "Wrong Part Scanned" alarm, stops the packing process, and requires the operator to restart the packing sequence from the beginning. The master carton is designed to hold 12 parts. The operator must successfully scan and verify all 12 parts before the carton is considered complete. After all 12 parts have been successfully verified: The system automatically generates and prints a master barcode label for the carton. The master barcode label is then affixed to the outside of the carton for identification and traceability. This system ensures that only the correct parts are packed, provides complete traceability, prevents part mix-ups, and improves overall packing quality and production reliability. Horner Engineering India Private Limited Horner Automation & Solutions Group #Automation #Hornerocs #Barcodesystem #Programming #PLCprogramming #Hornerautomation #XLEOCS

#automation #plcprogramming #hmi #industrialautomation #autoclave #controlsystem #deltaplc #machineautomation #hornerocs #horner | Srinijan Automation SolutionsSuccessfully completed autoclave machine program modification and testing. The update includes: • Pressure and vacuum scaling adjustments • Heating and cooling rate correction • Trend and graph monitoring improvements • Segment data loading through SD card • Report file viewing and verification • HMI modifications and logic corrections Program testing and verification completed successfully. Specialized in PLC Programming, HMI Development, Process Automation, and Industrial Troubleshooting. #Automation #PLCProgramming #HMI #IndustrialAutomation #Autoclave #ControlSystem #DeltaPLC #MachineAutomation #hornerocs #Horner

#automation #emergencysupport #hornerocs #horner #plcprogramming #programming #reducedowntime | Srinijan Automation SolutionsEmergency-Based Conversion from Horner XL7E (Model 4) to Horner X7 to Prevent Production Loss An emergency migration was carried out to replace the existing Horner XL7E (Model 4) PLC with a Horner X7 PLC to prevent production downtime. The original XL7E controller was configured with 24 digital inputs and 16 digital outputs. During the conversion, it was identified that the onboard I/O of the X7 PLC did not match the existing hardware requirements. To overcome this limitation, a Horner XLE (Model 4) PLC was integrated as a remote I/O station. Communication between the X7 and XLE PLCs was established using Horner CsCAN communication, enabling seamless exchange of input and output data. One of the major challenges during the migration was the difference in available R registers. The original XL7E application utilized R registers up to R50000, whereas the X7 supports only up to R5000. As part of the conversion, all program references beyond R5000 were systematically reallocated to available registers within the X7 memory range while maintaining the original machine functionality. After completing the I/O mapping, register reallocation, communication setup, and program modifications, the application was successfully commissioned on the Horner X7. The machine was tested thoroughly and found to be operating successfully without production loss. Horner Engineering India Private Limited Horner Automation & Solutions Group #Automation #Emergencysupport #Hornerocs #Horner #PLCprogramming #Programming #Reducedowntime

#automation #plcprogramming #hmi #industrialautomation #injectionmoulding #controlsystem #machineautomation #hornerocs #hornerautomation | Srinijan Automation SolutionsInjection Moulding Machine – Wrong Raw Material Prevention System Using Barcode Scanning A barcode-based raw material verification system will be implemented to prevent loading the wrong raw material into the injection moulding machine. Each raw material bag contains a unique barcode. Before loading the material, the operator must scan the barcode on the raw material bag. The scanned barcode will be compared with the master barcode (or approved material code) assigned to the product currently running on the machine. If the scanned barcode matches the master barcode, the raw material drum will unlock/open, allowing the material to be loaded. If the scanned barcode does not match, the system will generate a "Wrong Material Scanned" alarm, and the raw material drum will remain locked to prevent incorrect material loading. This system ensures that only the correct raw material is used for the current production, reducing the risk of quality issues and material mix-ups. Horner Engineering India Private Limited Horner Automation & Solutions Group #Automation #PLCProgramming #HMI #IndustrialAutomation #InjectionMoulding #ControlSystem #MachineAutomation #Hornerocs #HornerAutomation

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