Optimizing PLC Controls
E2M, Inc. (E²M) and Polytron, Inc., Norcross, Georgia, have developed a new method of debugging and optimizing PLC based control systems for both new and existing manufacturing systems. This new process, called PolySim(SM), enables E²M and Polytron to enhance productivity and reduce start-up time.

High-speed packaging lines are susceptible to stability problems. They require an intricate and well-balanced control program to ensure optimal throughput and efficiency. In the past, the control programs for the systems could only be tested and debugged as the last step in a project, often taking quite a bit of time and placing tremendous pressure on the controls engineers to complete the project. The PolySim process can reduce the duration of the project as well as this pressure by allowing much of the debug process to take place before the equipment is installed. With most of the controls debug done prior to installation, the time it takes to start up a system is substantially reduced.

A More Reliable Control System
PolySim allows the controls engineers to complete the testing and debugging of the control system earlier then was previously practical. With the PolySim process, the PLC controller receives the same responses as it would from the real system, allowing the controls engineers to significantly debug the actual control system code on the PLC before the equipment is even delivered. Further, the model environment allows for controlled and repeated testing. The end result is a more reliable control system available at the completion of construction and a compressed project schedule.

Enhancing Productivity
PolySim is also used to enhance productivity on manufacturing lines by solving productivity problems in an office without disrupting production. Additionally, it allows solving productivity problems in a shorter period of time. If a specific application area is having on-going controls problems, you can use PolySim to emulate that section of the line and run various solution scenarios without ever having to shut down your line for testing. This allows the controls engineers to find a solution via emulation and the line is only shut down for the short period of time it takes to make the recommended changes. This allows your production to remain stable during the discovery process, and then increases productivity quickly once the solution has been applied to the line.

Increasing Value
While traditional methods of applying simulation technologies in the packaging industry have allowed cost savings in the early stages of design, the PolySim process increases value during the design, start-up, training and production phases of a project. This saves valuable time in the field, and compresses the overall project schedule, resulting in more cases out the door - sooner.

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