industrial-control-engineering

ICE Electrical - Experts in Automation for Various Industries

Mon, 17 Feb 2025 18:03:37 GMT

HOW ICE HELPED SCALE UP PRODUCTION OF THE CATERPILLAR 797 MINING TRUCK

Improving Efficiency and Reducing Costs with Wheel Flushing Automation

The mining industry demands robust and reliable equipment to withstand the harsh conditions of operation. At the heart of this reliability lies the performance of heavy-duty mining trucks. To ensure optimal performance and minimize downtime, rigorous testing and maintenance of critical components like wheels are essential.

ICE was tasked with a significant challenge: to improve the operation and efficiency of a highly automated rear wheel flushing machine cell for Caterpillar in Decatur, Illinois. This machine cell played a crucial role in testing and maintaining the rear wheels of massive mining trucks, including models 777, 785, 793, and 797.

The Challenge:

The initial wheel flushing process proved to be time-consuming, with cycle times exceeding 45 minutes per wheel. This sluggish performance hindered production throughput and significantly impacted Caterpillar's overall manufacturing efficiency. Furthermore, the high warranty costs associated with wheel-related issues presented a substantial financial burden.

The Solution:

ICE founder & engineer Brad Morton embarked on a comprehensive project to optimize the wheel flushing process. Key improvements focused on:

Hydraulic System Enhancements:
Upgraded hydraulic filtering systems to minimize contamination and ensure optimal fluid cleanliness.
Refined hydraulic control systems for smoother and more efficient operation.
Control System Optimization:
Modernized the Allen-Bradley SLC500 control system for enhanced performance and responsiveness.
Implemented Variable Frequency Drives (VFDs) to control the 100HP motor that rotates the massive 100-200 ton truck wheels.
Temperature Control:
Improved oil temperature heating and control systems for the two 500-gallon reservoirs to maintain optimal operating conditions.
Data Acquisition and Analysis:
Integrated a Pamas particle counter for real-time fluid cleanliness monitoring.
Developed custom software to communicate with the particle counter via RS232C and issue commands to the Allen-Bradley Visual Basic Card.

The Impact:

These strategic improvements yielded remarkable results:

Drastic Cycle Time Reduction: Cycle times were significantly reduced from 45 minutes to approximately 15 minutes per wheel, a threefold increase in productivity.
Enhanced Production Throughput: The accelerated process enabled Caterpillar to increase the production volume of mining trucks.
Reduced Warranty Costs: By improving wheel performance and reliability through optimized flushing and maintenance, Caterpillar experienced a substantial reduction in warranty claims, saving millions of dollars annually.

Machine Specifications:

Control System: Allen-Bradley SLC500
Motor Drive: VFDs controlling a 100HP motor for wheel rotation
Hydraulic System: 6 hydraulic pumping units with advanced filtration
Temperature Control: Systems for heating and controlling two 500-gallon reservoirs
Fluid Monitoring: Pamas Particle counter with RS232C communication and custom software integration

Conclusion:

The successful implementation of the MD4855 Gen I Wheel Flusher project demonstrates ICE's expertise in industrial automation and its commitment to delivering innovative solutions that enhance efficiency, reduce costs, and improve overall operational performance. This project serves as a testament to the power of integrated systems, advanced controls, and data-driven decision-making in optimizing manufacturing processes.

Industries: Heavy Industrial, Plastics, Water & Wastewater, High-Speed Automation, Oil & Gas Refineries, Automotive, Robotics

Ignition Software for Seamless Energy Management

Fri, 31 Jan 2025 19:16:19 GMT

Ignition for Energy Management

Harnessing Ignition Software for Seamless Energy Management in Industrial Plants

In today’s industrial landscape, energy efficiency and plant reliability are paramount. As industries move toward decarbonization and optimized energy consumption , integrating solar inverters, battery storage systems, energy monitoring devices, and variable frequency drives (VFDs) into a centralized data system is crucial. At Industrial Control Engineering (ICE) , we specialize in developing custom software solutions using Ignition software to seamlessly connect these critical energy assets, empowering plant operators with real-time insights and automation for maximum efficiency.

Why Centralizing Energy Data Matters

Industrial plants are increasingly adopting renewable energy sources and smart energy management to reduce costs and carbon footprints. However, energy assets often operate in data silos , making it difficult to monitor performance, optimize usage, and ensure reliability. A unified software solution can:

✅ Provide real-time visibility into energy generation, storage, and consumption

✅ Detect faults and inefficiencies in solar inverters, battery systems, and VFDs

✅ Enable automated responses to energy fluctuations and peak demand

✅ Support data-driven decision-making for cost savings and sustainability

How ICE Leverages Ignition Software for Energy Data Integration

Ignition by Inductive Automation is a powerful SCADA and IIoT platform that allows us to connect diverse industrial devices and create custom energy management solutions . Here’s how ICE uses Ignition to integrate solar inverters, battery storage, energy monitoring devices, and VFDs into a seamless, centralized system:

1. Solar Inverter Integration

Solar inverters convert DC energy from solar panels into AC electricity. Many modern inverters support Modbus TCP/RTU, OPC UA, or MQTT —protocols that Ignition can natively communicate with. Our software solutions allow operators to:

Monitor real-time power output, voltage, and efficiency
Receive alerts for inverter failures, temperature issues, or shading problems
Analyze historical energy production trends to optimize solar utilization

2. Battery Storage System Monitoring

Battery storage is essential for balancing energy supply and demand. Using Ignition’s MQTT and OPC UA modules , ICE integrates Battery Management Systems (BMS) to:

Track charge/discharge cycles and battery health
Predict energy storage availability for peak shaving strategies
Automate load shifting based on energy pricing and demand

3. Energy Monitoring Device Integration

Industrial plants deploy smart meters and energy monitoring sensors to track energy consumption across production lines. ICE customizes Ignition dashboards to:

Aggregate energy consumption data from multiple sources
Visualize real-time demand curves and cost trends
Identify energy inefficiencies in processes and equipment

4. Variable Frequency Drive (VFD) Optimization

VFDs control the speed of motors in pumps, compressors, and HVAC systems, significantly impacting energy efficiency. By integrating VFDs into Ignition, we enable:

Automated speed adjustments based on real-time energy demand
Predictive maintenance alerts to prevent unplanned downtime
Energy savings analysis to optimize motor performance

Empowering Plant Operators with Actionable Insights

ICE doesn’t just centralize energy data—we ensure operators have the right tools to make informed decisions. With custom Ignition dashboards, alarm notifications, and historical analysis tools , plant operators can:

⚡ Detect inefficiencies before they become costly failures

⚡ Optimize energy usage dynamically based on real-time data

⚡ Reduce downtime and increase equipment lifespan

⚡ Achieve sustainability goals and lower carbon emissions

A Future-Ready Approach to Industrial Energy Management

By leveraging Ignition software , ICE delivers scalable, flexible, and secure solutions for industrial energy management. Our expertise in custom software development ensures seamless integration with existing infrastructure while enabling future expansions as energy strategies evolve.

Are you ready to take control of your plant’s energy efficiency and reliability? Contact Industrial Control Engineering (ICE) today and let’s build a smarter, more sustainable industrial future together!

About ICE: Industrial Control Engineering (ICE) specializes in designing and implementing custom SCADA, IIoT, and automation solutions to enhance energy efficiency and industrial reliability . With deep expertise in Ignition software and industrial communication protocols , we help manufacturers and energy-intensive industries seamlessly integrate, monitor, and optimize their energy assets.

Introduction to ICE

Mon, 20 Jan 2025 05:37:15 GMT

Industrial Control Engineering, LLC is a confluence of Automation Engineers & IBEW Electricians under one umbrella.

We wish all of our customers and fellow citizens a wonderful 2025 and are excited to introduce you to our parent and founding company Industrial Control Engineering, LLC ! ICE was founded in 2003 by Brad Morton after spending several years in the automation industry and is the original company name of Morton Solar & Electric .

Our story...

It all started in Decatur, Illinois working for Caterpillar, Inc. mining truck division. While working for a small Evansville based company called Alfab Metals Corporation, my job was to design the electrical control systems for numerous machines to assemble mining trucks. What is an electrical control system? It's the power distribution, PLC Enclosure, HMI, and the software that goes into the machine. In other words, it's the 'brains' of the machine.

Remarkably, about the this same time, Caterpillar was in the process of releasing the 797 Model which was to be the largest mining truck in the world. And, several of our machines were built to perform some of final steps of assembly to the wheels, drivetrain, and rear-end (RAX - Rear End Assembly) of this enormous machine.

I spent almost 10 cumulative years supporting Cat's production of mining trucks & graders. It was a job I cherished and loved. Can you image being able to watch a 3,200HP diesel engine being started for the first time on a piece of equipment that you had such a major contribution to create? That was just part of the satisfaction that I was able to enjoy. Additionally, the assembly equipment that we created helped Caterpillar produce trucks more reliably, at faster cycle times, and better quality. We knew the results of our work was helping make Caterpillar more profitable and improve the operation of their equipment for thousands of customers all around the world? That was the rewarding career that I had while working for Caterpillar and part of the catalyst of the desire to save our customers money with solar, whether it be a residential home owner or a large corporation such as AstraZeneca.

WE HAVE ALWAYS STRIVED TO DESIGN & BUILD SOLAR ENERGY SYSTEMS CATERPILLAR TOUGH!

What is our business plan for 2025?

Morton Solar & Electric will continue to focus on residential & small commercial solar & battery storage projects in the Tri-State region. Our service area is approximately a 100 mile radius within Evansville, Indiana. We will continue to build our presence in Southeast Illinois from our office in Mt. Carmel, and help build the Western Kentucky solar market.

Industrial Control Engineering (ICE) will offer controls engineering and products to water facilities and manufacturers across the United States. We will also offer controls solutions to other business sectors such as Utilities, Refineries, Manufacturing, Automation, etc.

ICE Electrical Services will offer electrical & technical support services to facilities within 100 mile radius of Evansville, Indiana. This is our electrical contracting division for industrials that need high-tech support. We employ highly skilled IBEW electricians and can support all electrical support needs from top to bottom.

WATCH ICE AND HELP US GROW!

Just as Morton Solar has established itself as the pinnacle of quality solar energy systems in Indiana, ICE will strive to build the world's most efficient water treatment facilities.

In the face of climate change, we want to help provide life supporting sustenance to humanity in a more efficient and more resilient ways.

We bring a higher level of automation and a fresh perspective of renewable energy to the water industry.

We are a small company that's already made a MASSIVE impact and will continue to do so.

We are a Certified B Corporation and will continue to use our business as a force for good!

Smart Water Processing for Life

Wed, 01 Jan 2025 18:07:04 GMT

Empowering the Water Industry with Automation & Sustainability

What We Do -

We empower water plant managers by integrating advanced automation that provide precise control over key operational parameters, enabling lower operating costs, and improved reliability. Our custom software and control architecture gives the operator the ability to manage setpoints and alarms for pumps, filters, mixers, and valves. This results in enhanced energy efficiency, reduced energy costs, and a more reliable and sustainable water processing plant. With our solutions, we help modernize plants to deliver smarter, greener, and more resilient performance.

How We Work -

We start with a comprehensive assessment of your existing operation to understand your plant’s unique needs. From there, we design a customized plan to integrate a Programmable Logic Controller (PLC)—the brain of your operation—and a Human Machine Interface (HMI)—the control interface—into your system, giving you complete control and visibility. With years of experience in the automation industry, we ensure you get the maximum functionality from your Variable Frequency Drives (VFDs) (utilizing Ethernet/IP protocols) and any other ancillary processing equipment in your plant. Our expertise helps transform your water processing facility into a more efficient, reliable, and cost-effective operation.

Capabilities -

ICE boasts extensive experience in the automation industry, delivering custom control designs tailored to diverse industries. We bring a fresh perspective by integrating automation and renewable energy solutions, particularly in the water sector. As a vertically integrated company, we manage every aspect of a project—from conception to completion and ongoing support—ensuring seamless, silent, and secure solutions. Our track record includes successful projects for esteemed organizations such as Caterpillar, Inc., AstraZeneca Pharmaceuticals, Vuteq Corporation, and Indiana American Water. We hold certifications from Avetta, ISNetworld, and the Consortium of Construction Safety, underscoring our commitment to excellence and safety. In partnership with Morton Solar, LLC, we have designed over 1,500 solar energy systems for residential and commercial clients, highlighting our leadership in renewable energy solutions.

Why Choose Us -

Our diverse expertise in automation, renewable energy, and electrical contracting empowers your water processing facility to operate efficiently within budgets. By integrating cutting-edge solutions, we not only help save your community money but also enhance the overall quality and reliability of your water supply. With us, your plant becomes a smarter, greener, and more cost-effective operation.

Background -

Founded in 2003 as an electrical engineering contractor for Caterpillar, Inc., ICE quickly established itself as a reliable leader in the automation industry. In 2005, ICE expanded into solar energy by founding Morton Solar, a pioneer in the solar industry.

Fault Logic is critical in automation to meet productivity goals

Fri, 20 Dec 2024 19:34:49 GMT

Does your automated production equipment stop running without giving the operator a fault message telling them why it has stopped? This is a common occurrence in manufacturing facilities with various types of automated production machinery. The cost from lost production while the operator and maintenance technicians scratch their heads trying to figure out why the machine or assembly line has stopped can be tremendous. Most of the time it’s because of inadequate or unfinished programming in the Programmable Logic Controller (PLC) and HMI that operates the machine. This can consist of lines of code, or ladder logic, which must be entered for each type of fault or condition that prevents a machine from running, or which could cause an unsafe condition. Each one of these inputs, or fault conditions should be entered into the logic along with a message on the display stating the input number which it is associated with. In the automation and machine building industry, there are time constraints to build highly complicated equipment and often times the machine is shipped without adequate runtime to discover all of the fault conditions. It can sometimes take months or years of runtime to encounter different situations which cause poor production performance.

For example, as an actuator performs work, or cycles, it’s bearings can wear and cause increased bearing friction, and thus increased current in the drive motor. With adequate fault programming, the increased drive motor currents can be detected and the operator can be alerted so that maintenance can be performed at planned downtimes versus during an emergency stoppage from a catastrophic bearing failure. And, we all know that planned preventative maintenance is much less costly then unplanned downtime.

Sometimes getting all of the fault conditions programmed into a PLC can be daunting on large assembly lines with hundreds of inputs and outputs and motor drives. But, it can pay dividends on the productivity of the equipment by reducing downtime. With Variable Frequency Drives, there can be several fault codes which can be monitored and displayed on the HMI so that equipment operators can see what is going on instead of having to wait for a technician to plug in a laptop.

The next level of fault monitoring would be to add fault condition data recording to capture and store the amount of downtime per fault condition. Over time, this will give production managers a picture of which fault conditions are causing the most downtime and help understand where design improvements in the equipment need to take place.

ICE has several years of experience in the automation industry and specializes in programming and debugging automated assembly lines, work cells, indexing tables, and almost any type of automated assembly equipment. We are trained and certified in Rockwell Automation products and can help continuously improve the productivity of the equipment in your facility and handle any electrical maintenance or construction projects for your ongoing needs. We are a team of highly trained engineers and IBEW electricians in one company that are passionate about solving problems and improving the efficiency of your operation.

Kevin Simcoe and the Caterpillar Wheel Flusher

Fri, 22 Nov 2024 17:22:11 GMT

I am dedicating this article to Kevin Simcoe. He was a hydraulic hero and mechanical mastermind that I had the privilege to work with on many projects for Caterpillar's Decatur plant. He was a world class problem solver and a positive individual that inspired creative ingenuity to those that work around him. Kevin was not only the mechanical engineer on his projects, but he could also fabricate, weld, and assemble anything that he could envision. And, some of his inventions and innovations saved the giant corporation of Caterpillar millions of dollars by improving the productivity and efficiency of the manufacturing of their mining truck wheels. One of which happened to be the rear wheel of the Caterpillar 797, which was that largest truck in the world at that time.

The first project that I was lucky enough to work with Kevin on was the MD4855 Rear Wheel Flusher for the 100 ton and up product line. These were the truck models 777, 785, 789, and 793 which was the 240 ton truck. The MD4855 wheel flusher was an oily greasy monster of a machine that required skill and experience to operate. It had several deficiencies that needed to be improved. But, it performed a critical step in the production of mining trucks in that it was the last stop of the rear wheel before it was bolted to the truck. And, it's purpose was to lubricate, clean, and test the wheel assembly's massive spindle bearings and braking system, and to flush out as much dirt and contaminates as possible.

My job as a controls engineer was to create the software to make Kevin's inventions come to life and function reliably and create the operator interfaces on the HMI so that employees could figure out how to run the machine.

This is the MD4855 Rear Wheel Flusher in Caterpillar's Decatur, Illinois plant. The spindle gears were driven by a 100hp motor and variable frequency drive.

Here is a list of improvements made to the machine over a 2-3 year period:

Oil flow through wheel spindle bearings not reaching all of wheel. Kevin designed new rotary union and cover plate to circulate oil one end of wheel to the other. The other section of the wheel contains the spindle gears and cover plate. The inner section contains the inner bearings, hub, and wet-braking pads and plates. Kevin also designed a high pressure spray wand which would rotate and spray oil inside the gears and bearings to dislodge the particulars so that they could be filtered out of the lubrication system.

Pamas Particle Counter - Kevin designed the hydraulic circuitry to incorporate a Pamas Particle Counter into the machine. This allowed the oil from both the brake and bearing cavities to be tested for cleanliness. By incorporating the Pama Particle Counter, the cycle time of each wheel was reduced from 45 minutes to 20 minutes which improved the production capacity of the machine. Kevin was the father of the Pamas Particle counter at the Caterpillar plant and eventually incorporated into numerous machines. With these device automated into the process, the ISO cleanliness rating could be recorded and documented with the serial number of the wheel for a much higher traceability.

Improved filtration - Kidney loops were added to the massive 500 gallon reservoirs where oil was kept at a constant 125F temperature for proper viscosity and flow. Differential pressure sensors were added to the main filter banks to monitor and optimize filter life. These filters were expensive and it was crucial to get the maximum life and filtration capacity from the filter bank.

This is the rotary union and flange plate on the drive end of the wheel. The rotary union allowed oil to exit out of the gear drive end for better cleaning and flushing of the bearings and inner surface areas of the wheel.

Vickers Proportional Braking Valve - Kevin redesigned the service brake circuit to include a proportional pressure valve to simulate the actual braking pressure of a human foot while driving the truck. The previous circuit only allowed full pressure which locked the wheel up. The proportional valve allowed a lower braking pressure to permit the wheel to spin and 'defuzz' the braking pads and surfaces. This required extensive debug of both the hydraulic circuit and the machine logic due to the extensive surface area of the braking pads and plates. Kevin said "pretend you are driving the truck down a Gibson County haul road and write that into the code". So, that's what I visualized when writing the code.

This is the Vickers Proportional Braking valve which required extensive debug, but resulted in major improvements to the braking operation of the machine, and a realistic braking cycle on the wheel.

All of these improvements to the MD4855 Gen I wheel flusher contributed to a higher quality wheel in the field with less contamination resulting in a longer life for Caterpillar Mining Truck wheels. Many of these modifications were fabricated and installed on the plant floor in Decatur, and most required extensive debug. Minimizing production downtime was crucial at all times, therefore pressure was intense. Some improvements were made over weekend shutdowns and required extensive hours just to get the machine back up by Monday morning. But, Kevin always came through and knew that the culmination of his work would save Caterpillar millions of dollars and that his work would be appreciated. And, I had the incredible pleasure to tag along for part of that ride.

The brains of the machine: an Allen-Bradley SLC 505 PLC with numerous analog and digital I/O. An AB Basic card communicated with the particle counter.

And, this project eventually allowed me to start a business and become an entrepreneur and start a renewable energy business where one did not exist before. And, I owe at least some of the out-of-the-box thinking to Kevin, and I'm grateful for the opportunity to work with him.