Mitsubishi PLC

Automated Cutting Machine HMI System (CC05 SmartLink) The Challenge: The client required a modern Human-Machine Interface (HMI) to automate the workflow of their CC05 Cutting Machine. The system needed to bridge the gap between operator barcode scanning, centralized production databases, machine PLCs, and label printers in a seamless manner. Key Difficulties: Establishing direct communication with Mitsubishi FX5U PLCs over a TCP/IP LAN without relying on expensive third-party OPC servers. Automating the label printing process by sending raw commands directly to Zebra printers without using standard Windows print drivers, ensuring zero delay. Providing robust offline capabilities for operation history logging and instant label reprinting in case of hardware or network issues. Solution Architecture WP Solution developed CC05 SmartLink, an industrial-grade C# .NET 8 WPF application acting as a comprehensive middleware HMI. The workflow is entirely barcode-driven; operators simply scan a Control Number or Order Number to automatically retrieve production parameters (such as Cut Length, Project No, and Model) from a central SQL Server. Once the machine is commanded to start, the system communicates directly with the PLC, listens for the “Machine Complete” signal, and dynamically generates and prints Zebra ZPL labels. ...

CSIAPipeBender: High-Precision Tube Bending Controller Problem Statement: In traditional tube bending, operators often struggle with complex geometry calculations. converting a 3D drawing (XYZ coordinates) into machine actions (Length, Rotation, Angle) requires advanced mathematics. Additionally, physical factors like Spring Back (metal elasticity) and Elongation (stretching) often lead to inaccurate bends, requiring significant trial and error. The Challenge: Complex Math: Manual calculation of bend sequences is prone to human error. Material Behavior: Different tube materials react differently; a standard fixed program cannot account for spring back variance without a smart compensation algorithm. Our Solution: PC-Based CNC Architecture We developed CSIAPipeBender, a Windows-based HMI/Controller that acts as the “Brain” for the machine, while the Mitsubishi PLC acts as the “Muscle.” ...