Services

Plant Floor Automation and Integration

Recipe Enforcement and Material Tracking Systems

PSI has been involved in a large number of material tracking and recipe control deployments over the years. These systems incorporate an intrinsically safe mobile device with a built-in barcode scanner as the primary operator interface to the system. Broadly, two types of systems are being used: process verification and inventory management. Process verification is used to ensure that the correct process ingredients and procedures are enforced. Out-of-place material or operator errors can cause the process to lock down until supervision clears the error. As material are handled through the plant the quantity and location is logged.

  • Barcode Labeling and Tracking for Chemical Preparation
  • Recipe Control for Medium Caliber Blender
  • Logging for Visual Inspection of MK90 Rocket Motors
  • Labeling and Tracking for NC Dewatering/Compacting Drums
  • Programming and Integration for Scale in NC Wringer House
  • Labeling and Tracking for NRE Canisters
  • Propellant Inventory Tracking and Storage (PITS)
  • Recipe Control for Single-base Material

Design and Implementation of Process Control Systems (Batch and Continuous)

These systems involve an in-depth knowledge of the chemical process and the mechanical equipment used. The most common elements of a process control project will involve PLC controls (networked nodes and remote I/O), specialized instruments (mass flow meters, analyzers, etc.), data acquisition and logging, and multiple operator interface screens.

Environmental Compliance

Environmental Permit Systems

There are two methods of disposing explosive waste, each governed by specific DEQ permits. These systems typically are a combination of a website front-end and a SQL Server database. Waste chemical analysis from the main lab is logged in the database for each waste stream on a monthly basis. An area operator will use the web interface to compose batches of waste material and verify that the proposed incineration complies with the DEQ permit. Environmental engineers are responsible for maintaining the quality of the waste stream analysis and use a web interface to access and approve lab data.

  • Explosive Waste Incinerator
  • Open Burning Ground

Test and Measurement Systems

PSI has built and programmed numerous test systems and would be interested in discussing and fulfilling your Automated Test Equipment (ATE) needs.

Both in the lab and on the factory floor ATE enables customers to implement traceable and consistent quality standards. From testing electronic subassemblies on the production line to completing extended burn-in testing, ATE systems are an ideal solution for cost effective, in-process Quality Control (QC).

Nearly all electronic and mechanical products undergo some sort of final testing. As the sophistication of these tests increases, so does the need for automation. This is where ATE plays an important role. The advantages of using automated testing over manual methods are many:

  • Consistency. Once a test has been automated it will always execute the same way. Test results are always recorded in the same manner and can be easily placed under a periodic backup procedure. Changes to test procedures require software and possibly hardware changes which are tightly controlled.
  • Documentation - Whether you are an ISO 9001 supplier or your organization uses other methods to document product quality, ATE ensures that the proper tests have been run and recorded. If necessary, an electronic paper trail can be generated for each item or batch you ship.
  • Safety - In some situations, you would prefer that testing be done in a hands-off manner. Manual testing may risk exposing operators to chemicals, high voltages, or other dangers that could be avoided through test automation.
  • Economy - In many cases, it simply no longer possible to complete the job using manual methods. For electrical subassemblies, a lot size of only a few hundred units can justify the ATE solution. As production quantities increase the economies of scale become very convincing.
For the last twenty years or so, ATE systems have been built with 19-inch rack mounted instruments controlled by a personal computer via General Purpose Interface Bus (GPIB). These systems have been predominately programmed using National Instruments LabVIEW®, although C, C++, and Visual Basic are not uncommon. Sometimes custom hardware is needed for situations where rack mounted instruments are not available.

  • Automated Test Equipment (ATE)
  • Non-destructive (vision system, X-ray, ultrasound, etc.)
  • Material Properties
  • Controls for X-Ray Inspection of MK90 Rocket Motors
  • MACS Lap Scale Logging
  • Control and Data Acquisition for Two-Inch Rheology Press
  • Software for Ultrasonic Imaging of MK90 Rocket Motors
  • Munitions Quality Testing
  • Multi-axis Stepper Motor Controller

Mechanical Test Systems

PSI has designed, modified, and instrumented a variety of mechanical test systems. We have been involved in mechanical test projects from the conceptual design phase through actual testing to the final reporting of results.

For example, PSI has previously designed and implemented a materials test frame for testing high speed tension, compression, and shear. The device controled cross-head speeds from 0 to greater than 2 m/s in an environment with controlled temperature (-70 to 150°C) and humidity (5 to 95%). These features made this equipment ideally suited for testing adhesive, natural fiber, and polymer based materials.

We can assist you in the development of your own mechanical test systems.