IMC Control Systems

The Problem
Machines last 30 years or more; control systems are typically obsolete after seven years. Several Factors have contributed to making the situation worse. Machinery manufacturers tend to concentrate on mechanical engineering with control systems receiving short shift. The result has often been poorly designed systems that become obsolete long before their time.

Advantages of Open Architecture

Why Open Architecture? The Pacesetter is based on "Open Architecture Hardware". This simply means that specifications are public and therefore parts are available form multiple sources. With no dependence on specific vendors, you are protecting against supply disruptions or high prices. You will never be held hostage for an inflated cost replacement part. Open architecture encoder interface hardware does not exist, however. Rather than rely on an outside vendor proprietary parts, IMC has designed its own.

Linux Operating System

IMC's new Pacesetter; 3.0 software runs under the Linux operating system. Linux is a stable open sources 64-bit license free Unix variant that supports full graphical user interface, large memory space, easy customization, maintainability and portability. It has all the advantages of Windows without Windows inherent problems. Linux is crash resistant and doesn't require an uninterruptible power supply. No shutdown procedure is needed; power can simply be turned off.

Benefits Include:

  • Simplifies new development
  • Provides true graphical user interface
  • Provides Internet connectivity with remote diagnostics and software updates
  • Enables single or multi-plant monitoring and production control
  • Includes SQL Data Base, which simplifies data connecticity
  • Allows for fast PLC Interface simplifying design and reducing cost by eliminating redundant I/O
  • Allows for distributed architecture and the resulting reduction in inter-station wiring
Pacesetter 3.0 is backward compatibility with the original Pacesetter. The new Software, written in C, is based on he original C code. Cost to upgrade an older Pacesetter is modest.

Considerations When Replacing Controls

Cost
It seems simple, but cost is often an extremely complex issue. Initially of course is upfront cost; how much to get the Controls installed and working on your machine. Less obvious though is cost over the lifetime of the new controls.
Ease of Use
Pacesetter 3.0 can offer the operator a single page view of all he machine stations. Pacesetter's graphical user interface is simplified; only the necessary information is presented, avoiding over-complex interface decoration.
Expertise
IMC specializes in replacement control systems. IMC's management and engineering teams are led by the former Managers of Control Engineering and the designer of Langston's computer control systems.
Reliability
Linux is the choice OS when resistance of viruses and crashing is mandatory. Linux is a stable open sources 64-bit license free Unix variant that supports full graphical user interface, large memory space, easy customization, maintainability and portability.

Possible Return on Investment

ROI for a Typical Two Color Flexo Folder Gluer
Shifts Per Day
2
Set-ups per shift
5
Working days per month
21
Average reduction in set-up time due to Pacesetter
15 Minutes
Machine profit contribution per running hour
$180.00
This equates to 2,520 set-ups per year Saving 15 minutes per set-up gives you 630 additional hours of machine running time available every year. Which can generate - Annual Profit Increase of $113,400 PER MACHINE
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