Keystone Automation has experienced electrical engineers who can tackle any project related to automation and manufacturing. The equipment shown in our design and fabrication section had their controls designed and programmed by the electrical programming group. We additionally provide controls programming for other brands of equipment. We provide programming for ALL major brands of PLCs, Servo’s and operator interfaces. We offer drive solutions with servos, steppers, vector drives and variable frequency drives. We’ve designed everything from simple motor control stations to coordinated motion servo systems.

The services we offer:

• PLC Programming
• Operator Interface programming
• SCADA Integration
• Motion and Drive Control Systems
• Advanced troubleshooting
• Vision system integration

There are a variety of types of electrical controls which we are extremely familiar with. They range in size and complexity from a simple motor starter or solenoid control to high end servo systems with coordinated motion. Below are some examples of the controls we offer:

Simple motor controls

These systems are used for control of conveyors, mixers or any number of systems with start/stop functionality. There is usually a fused disconnect switch and a motor starter. There may be a control transformer, an emergency stop circuit and push-button controls. The logic is typically controlled by relays or a timer. A variable frequency drive may be used. Simple motor controls can sometimes be used in very large cabinets driving multiple conveyors. We also provide schematics and control panel fabrication.

PLC controls

We are experienced with most major brands of PLC’s including Siemens, Automation Direct, Modicon/Telemechanique, Omron and Mitsubishi. The majority of the PLC’s we sell are Allen-Bradley. We are able to use ALL Allen-Bradley PLC’s from Micrologix through the ControLogix platform. There are many options when using PLC’s for control. We typically determine the inputs, outputs and control voltage and establish a logical narrative of operation. Once the control scheme is developed, the schematics are drawn and the logic is programmed. After development and fabrication, testing and debug are performed until the machine is fully operational. We also can install a modem for remote troubleshooting.

Servo Controls

We are experienced with most major brands of servo and stepper systems including Parker, Lenze, Allen-Bradley and Oriental motors. We have built machines with single axis positioning and machines with 3 axis coordinated motion. As with PLC's, the options for servo control are endless. The pricing on servo systems has come down over the past few years and they are used for more applications than ever before. We not only provide high performance systems, we also provide training for in-house maintenance people on troubleshooting techniques. The most precise machine we have built is a wafer inspection system moving to 1 micron accuracy.

Servo Alternatives

Many applications are suitable for controls that do not require the positioning accuracy of a servo. A typical example is an indexing conveyor or a gantry system. We have built multiple machines with both linear and rotary indexing using a variable frequency drive and PLC control. An index flag is used to actuate two different proximity sensors. At the start of the index, the drive runs at high speed. When the first prox is hit, the drive decelerates to a minimal speed. When the second prox is hit, the drive stops. We also are able to get servo like performance from a variable frequency motor using a servo controller. We have used this in multiple gantry systems and have been able to get positional accuracy within 1/32” while moving a 1,000 pound load. The advantage of this is the ability to control a multiple horsepower motor moving a heavy load. We also use this same control for variable torque applications with very accurate control.

Operator interface and Data export

We have developed a number of systems to monitor and control processes. These include different types of operator interfaces (touch screens) from Allen-Bradley, EZ Touch, Parker, Eaton and Red Lion. Our selection depends on the application and the customer preference. A recent addition to the marketplace is the Red Lion operator interface. It has OPC Ethernet capabilities so we can export data from any brand of PLC to the front office. The data can be viewed on a spread sheet or web page. We have also developed different types of data export systems using Excel and National Instruments. The most complex system we have made to date exported hundreds of thousands of data measurements from a laser microscope measuring the depth of grooves to sub-micron accuracy. Our typical operator interface is for simple machine controls that gives operational control and alarm screens. Our alarm screens typically display three things: the alarm condition, the simple corrective action and the inputs and outputs for a technician to check. Most customers appreciate having a simple, easy to understand means to troubleshoot a problem.

Upgrades

We offer all sorts of upgrades to older control systems. Sometimes it is best to keep it simple and change out some bad wires or cables. Other times we completely tear out all the old controls and wiring and replace everything. We work with you, the customer, to decide the most cost effective solution that works within your budget and operational goals. We have years of experience with all sorts of industries including European machinery. We also provide safety upgrades to older equipment.

Service

We service what we sell. We also do installation and on site debug. We troubleshoot other manufacturer’s panels as necessary. Our service area is North America.

The controls we service: