Automated Software Control Systems

Once the production of a machine was only as good as the operator who operated it, with today’s technology that same machine automated can become a highly productive efficient piece of equipment. This once only a dream can now be achieved, because computers and electronic component have become smaller, faster, more reliable, and cheaper.  The future of automation is now only limited to the project designer’s imagination to develop the right program code to integrate the technology to a stagnate machine.  

Why automate

• Increase profitability
• Increase production
• Increase Safety
• Reduce the risk of human error
• Shortage of skilled workers

Benefits of automation over employees

• Always on time
• Does not get sick
• Does not have toilet breaks
• Works without complaint
• Works without the need of idol conversation
• Does not require Holidays
• No need to strike
• Does not complain about work conditions
• Does not suffer with fatigue
• Can make a programmed decision quickly
• Works efficiently in all types of weather
• No need for a pay cheque or superannuation
• No Lost Time Injury

Our Current Automation Project

JD Rail has brought an older style Tamping Machine which we will use as base machine for Automation upgrade. The original Tamping Machine was mostly dependant on an operator to trigger the functions for the Tamping Operation, which was very demanding on the operator and if the operator did not pay attention the Tamping Heads would smash into the sleepers causing damage either to the sleeper or the Tamping Head. One of the problems this machine and many of predecessors suffer from was problems with wiring and PLC systems, which became worse as the machine aged until it came a time that it was spending more time repairing problems rather than working. The system being designed has a much simpler wiring system with a quick view diagnostic for the mechanic to determine if the a problem is mechanical or computing/electronic problem which itself has a built in self diagnostic system. Once completed the Tamping machine will operate in two modes, one will allow the operator to operate the machine with software system only overriding when it is evident that a Tamping Tyne is going to hit a sleeper. The second mode will be where the Tamping will operate by itself with the operator giving the required parameters. The second option should make the Tamper Machine more efficient than its original specification as the program itself can make a choice faster than an operator can make a decision.

On the completion of the automation upgrade the same system can be fitted to most Tamping Machines already out on the market.  This gives potential to restore older machines to be more efficient than the original design.  To undertake the upgrade the original machine would require:

• Base overhaul of standards mechanical components
• Removal of existing PLC, wiring and sensors
• Fitting of additional Hydraulic controller in the original circuit
• Fitting of new control system
• Fitting all new sensors
• Fitting all new wiring

If you require further information on our Automation projects click here.