Showcase
Achieve Greater Control
Fraser Surrey Docks approached CFA when recurring failure of the analog electronics controlling Crane #2 threatened to force the company into decommissioning the aging workhorse. Capable of loading or offloading container ships at a remarkable speed and with a replacement cost ranging in the millions it was decided to attempt the installation of a PLC based device to monitor the analog systems aboard Crane #2.
In the event of certain known potential failures in the circuitry, compared against the requests for movements by the operator versus the actual motion of the machine, the PLC would over ride the existing controls and lock the load in place.
Techniques used in the software included basic DSP (digital signal processing) to detect failure of filter components in the power supply and yet be capable of ignoring normal “noise” caused by power components within the system.
Monitoring joystick positions in the operator cabin and comparing them to both the speed and direction of the load to recognize a runaway condition. Normal operations like pulling up to slow downward motion in a more aggressive manner had to be considered so as not to create false trips.
After development, installation and testing the entire unit went under the scrutiny of a group of Engineers from Transport Canada as well as the local Union and was granted a new lease on life.
OEM Remanufacturing is a world class facility located in Edmonton, Alberta, that provides diagnostic and repair service for Caterpillar equipment, including the Cat 797. The Cat 797 is a gigantic mining truck, used extensively at the Alberta Tar Sands, which is so big that it requires 550 Horse Power just to turn the transmission over in top gear. OEM Remanufacturing is currently the only facility in the world which is able to test its transmissions and torque converters in top gear. Once mounted on the computerized test bench developed by Hydracan and Control Freaks Automation, the transmission or torque converter of this behemoth can be run through all its stages and gear ratios. Hydraulic flows and pressures, as well as mechanical vibration are all carefully analyzed, and provide either a direct diagnosis of the required repairs or else a certification of fitness. A cost effective repair can then be initiated on the transmission or torque converter, or if still fit they can be returned to service.
Control Freaks Automation developed the control software and HMI (Human Machine Interface) for this system using the same principles it applies to all its projects. Ease of use, reliability and fail safe configuration of components and software – all wrapped up in a stunning interface that will both impress potential customers and make the operators proud to be at the helm of a state of the art device. The result is a machine that provides positive financial returns for the shareholders as well as creating job satisfaction for the employees responsible for its use, care and maintenance.
Top-Co LP is a leading edge manufacturer of down hole cementing tools and pipe centralizers for the oil industry. In 2009 they decided to build a state of the art test facility for their products, and again Control Freaks Automation teamed up with HydraCan Fluid Power (see the OEM Remanufacturing showcase) to build a modern test unit unlike anything currently operating in the world today. The three main sections of the test facility allow standard API (American Petroleum Institute) testing of their centralizers and cement valves. The flow loop alternately tests the valve components with flows of 20 barrels/minute (2380 litres/minute) for two hours and then back pressures the valves to 5000 psi (34400 kPa) for 15 minutes. After 24 hours of this cycle the valves are heated to 400°F (205°C) and back pressured to 10,000 psi (68800 kPa) in their custom pressure. Auxiliary transducer hook ups allow unique tests to be run on new and experimental products allowing Top-Co’s engineers to have a leading edge on all their competitors.