associated graphics that can clearly identify problem areas when faults occur.

The troubleshooting system usually enables quick repair to be performed by a mid-level maintenance person. But if the problem cannot be solved quickly on site, the Productivity3000 and the HMIs feature full remote access. With this feature, every I/O module, motor drive and sub-component connected to any of the communication ports can be accessed through the Ethernet data port—either locally or remotely through a standard Internet connection.

As a result, Casa Herrera can remotely view every motor drive parameter as well as every status register. The same goes for every rack, power supply and I/O module. The HMI screens also allow live, real-time remote viewing and control so the screen faults can be seen from anywhere. For detailed off-line analysis, the data logs, fault logs and event logs stored on a local USB memory stick can be viewed and downloaded using FTP.

“Since the commissioning of the first Productivity3000 tortilla line for True Foods, in Melbourne, Australia, we have gone online from California to monitor the control system in real time,” says Meade. “We have added customer-specific changes to the program, and we’ve tuned motor drive parameters. We also added new screen buttons and data trending features to the HMI, all in a matter of minutes.”

Future perfect

Casa Herrera sells many variants of this tortilla line: bigger, smaller, single line and double line. To accommodate these various types of lines, Memco devised a scheme by which the operating logic in each type of machine on the line is in a separate file. These files are called to action upon the system recognizing various control system components connected to the Productvity3000 via the Ethernet network.

The controller has the ability to ignore a completely disconnected rack or motor drive, and not fault the system. This means that end-users have the entire software program already loaded for any future possible expansion. All they need to do is power the equipment and plug it into the network.

This also means that Casa Herrera only needs to maintain one program for all tortilla lines sold with the Automation Direct control system. “We are currently working on control system additions to integrate machine vision and robotic handling to the product line. This will allow us to provide our customers with a complete turnkey manufacturing solution,” Meade concludes.

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