Motion Control

High-Precision Sliding Tester Control System Problem Statement: The client, a leading automotive parts manufacturer, relied on a manual or semi-manual process for endurance testing (cyclic motion) of their products. The existing control software was built on legacy technology (WinForms), making it difficult to maintain, prone to human error in parameter settings, and lacked the flexibility to adapt to new hardware sensors. The Challenge: Human Variation: Manual setups led to inconsistent test results (speed, acceleration, cycle counts). Legacy Debt: The old codebase was tightly coupled with specific hardware drivers, meaning replacing a broken motor or sensor required a complete software rewrite. Reliability: The system needed to run thousands of cycles continuously without crashing or losing data. Our Solution: Clean Architecture for Industrial QC We re-engineered the entire control system using Modern C# (WPF) and adopted Clean Architecture principles. The focus shifted from simple “control” to creating a robust “platform” for quality assurance. ...

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.” ...