SimTec's personnel have broad experience gained in the implementation of projects, both at home and abroad, and in different fields, including:

Automotive industry Goods industry Cement industry Metallurgical industry Power engineering Oil & Gas Chemical industry Waste-water treatment plants Road systems and tunnels Airfield lighting System upgrades Industrial networks Our own standard

Automation and robotization of press lines. The projects consisted of automating a complete process line by means of PLC's, industrial robots and operator panels. Press lines were usually composed of 4-7 presses with industrial robots operated between them. The line control included a production cycle that automatically fed sheets at the beginning of the line and formed them at subsequent presses. The transport of sheets from one press to another was effected by means of industrial robots. The production speeds obtained by such a line are up to 10 strokes per minute. The control included automatic tool replacement consisting of a complete retooling of the line for a new assortment. The tool replacement consisted of automatic replacing of press matrixes and robot clamps and automatic reloading of process parameters through collecting a new process description. The average replacement time did not exceed 10 minutes for the whole line..

• Synchronization of the press line operation. Based on an S7-400, a superior regulation algorithm was constructed for a line of seven presses operated in a continuous cycle (without stops between strokes). The maximum production speed of the press line is limited only by the capabilities of the press mechanical system. In the course of tests, a speed of 18 strokes per minute was achieved with a between-presses angular synchronization fault of less than 1°.

  Transport control. Our personnel participated in many projects consisting of automation of the process of moving car bodies/subassemblies within the factory area.

• Process control. The personnel of the SimTec company participated in numerous projects consisting of controlling and visualization of complete manufacturing processes, such as: body wax coating, paint shop oven control, body washing baths control or paint and lacquer preparation.
• Identification and process preparation systems. For many customers, our employees implemented identification systems based on the MOBY system or Siemens closed circuit television cameras. Based on modern visualization packages and their process preparation capacities, our employees developed different process management systems in respect of the data collected with the aid of identification methods. The systems significantly raised the efficiency and quality of work at operator stations.

• Batch Processes and Recipe Systems. Our employees have implemented numerous foodstuff production control systems basing on PLC controllers and superior visualization systems as well as MS-SQL and Sybase SQLAnywhere databases. We have experience in standardizing process preparation systems and implementing systems for diagnosing, reporting and archiving production and process parameters.

  CIP washing systems. Our specialists implemented control and visualization systems for CIP washing loops for different food industrial plants.

  Beer production control. The personnel of the SimTec company have participated in designing and have experience in beer production control systems. Our employees have developed software for such facilities as UT, BBT, CIP, a water purification plant, diatomaceous earth filters and beer centrifuges. We have also implemented superior systems for visualization, process preparation, reporting and data archiving in breweries.

  Sugar factory control. On the basis of Siemens' PCS7 standard, we have implemented complete sugar production control in a number sugar factories, starting from beet cutting plants, through diffusion, juice purification/densification, strike pan stations, centrifuges, drying plant and transport of finished products to silos. We have taken part in standardising software for a number of sugar factories. We provide a permanent technical support for control systems in sugar factories during sugar campaigns.

  

CEMAT Standard. Our employees have comprehensive knowledge and experience in implementing control and visualization systems for the cement industry. Based on Siemens' standards CEMAT and PCS7, we have realized projects for a number of cement plants in Poland and abroad. Cement plant control includes a complete technological process: component transport, weighing out raw material, raw material mill, homogenization, exchanger tower, pipe oven, coal batching, cooler, E-filter. SimTec provides permanent on-line service by means of the PC-Anywhere package for cement plants, which considerably shortens the time of reaction to notified problems. We have developed a complete modernization strategy for lime works with the purpose of transition to Cemat and PCS7 standards.

• Process control. The SimTec personnel have participated in automation of various metallurgical facilities, such as: flat iron reverse mill, rods continuous rolling mill, roughing mill, metallurgical furnaces, continuous casting of steel, E-filters, swaging machines, transports, water purification plants, hydraulic stations, finished product receipt-tying machines, etc.

Carburization. We have comprehensive knowledge and experience in implementing control and visualization systems for carburizing power units. The systems included unloading of wagons with coal-dust, forming storage stockpiles, transports, backfilling of power unit silos.

Oil platform In year 2005 SimTec Ltd. software specialists where involved in modernization of oil platform. Huge international team was managed by Siemens AG Oil&Gas division. The modernization task based on replacement of about 150 controllers S5-155U with old TELEPERM M system, with new S7-400 (CPU-417H) PLC's and PCS7 v6.1 system. Superior visualization systems where modernized with 6 redundant WinCC servers, 24 operator stations and big graphical screen-walls. SimTec specialists participated by PLC software preparation, WinCC visualization preparation and final acceptance tests (FAT). Customer required fault free system upgrade and installation without any disruption to platform operations, so the software had to be perfectly tested. According to Siemens AG information, the project was the biggest PCS7 implementation as one part, on the world.

• Batching systems. Our employees have a comprehensive knowledge and experience in implementing control systems and visualization systems for the chemical industry.
• Database systems. Based on the Industrial SQL Server and the InTouch package of the Wonderware company, we have implemented a data collection system for the washing powder production process. The data collected in the database are rendered available in the form of reports. The reports are generated by means of the Excel package. The user has a capability to generate a production report for an optionally selected period of time. Owing to the system implementation, the materials management in the plant was improved.

We have participated in designing and implementing control and visualization systems for wastewater treatment plants. We have knowledge and experience necessary for standardizing the wastewater treatment process. We are capable of implementing newest diagnostic techniques for the wastewater treatment process.

• Our employees are fully trained in newest tunnel and road system control techniques. We are capable of implementing tunnel control systems in conformity with the latest trends and applicable safety requirements.
  Some exemplary tunnel control structures as developed by our personnel: Example1 , Example2 , Example3

• Airstrip and taxiway. On many airfields, we have developed and implemented CALVERTsoftware for remote control and monitoring of navigation lighting. The system can be controlled from a number of independent sites (depending on the authorities assigned). The system computer monitoring enables comprehensive diagnosis of the airfield lighting condition. The redundant structure of the whole system ensures the highest operation reliability.
• Our employees have personal safety certificates authorising them to access secret information under the "Confidential" clause, which enables them to work at military facilities.

• S5 to S7 upgrade. In view of ceaseless progress and aging of electronics, our employees constantly participate in all kind of upgrades of Simatic S5 to S7 systems. We have the knowledge and experience necessary for upgrading control systems. We are able to adjust any control system to contemporary abilities. The company specializes in SIMATIC controllers, but we also have the knowledge and experience to optimize the control systems of other manufacturers.
• Visualization upgrade. In view of the unceasing progress in the field of visualization techniques, SimTec permanently participates in upgrading visualization systems that already belong to history. We offer modern visualization techniques conformable with the newest trends. The company personnel have complete expertise in the field of programming visualization systems basing on any tool package. SimTec specialists can also develop dedicated visualization software basing on their knowledge of higher order languages.
• Expansion with MS-SQL. Our personnel often participate in expanding capabilities of superior visualization systems. We extend the system capabilities with SQL database systems. As a result, the employer obtains a significant extension of capabilities and functionalities using our superior system. Apart from data collection and archiving, we provide capabilities for generating production reports for an optionally selected period and create instruments that enable building of production statistics as well as an archive diagnosis of events and disturbances. Upon the data collection system implementation, the employer obtains a data access from any point of the plant or the possibility to transmit data to the SAP type systems or similar.

• Networks. Modern automatics systems are often based on much extended communication structures. We have experience in designing extended industrial and computer networks. On the basis of electric or optical waveguide networks, we have implemented communication standards based on protocols Ethernet, ProfiNet, Profibus, AS-i, Modbus, Canbus, DeviceNet, etc. We have also implemented industrial networks based on Siemens SCALANCE components and GSM, GPRS components as well as radio-modems.

Own standard. Based on the team's experience, we have developed our own dedicated Simatic S7-300, S7-400 and PCS7 controllers standard and the WinCC visualization system. We have developed standard universal function blocks designed for controlling drives, valves and flaps, analogue measurements blocks, a universal step sequence block, industrial network diagnostics blocks, function blocks for cooperation with FANUC robots etc. Our standard function blocks can be used in Step7 as well as in PCS7 system in a CFC graphic form. For all standard blocks, we have created WinCC objects and control faceplates. The control faceplate enable a detailed diagnosis of a particular object. The use of the standard significantly improves our work. Moreover, the use of proven units is a guarantee of proper application operation. Flexibility. We can easily and quickly adjust our standard to the object specificity as well as to additional expectations. We are also able to adopt the standard to other type visualization systems or controllers.