If a roller detaches, then the lid falls before the mould opener and a line crash will occur.

By monitoring the lid and cavity with two photoeyes, the system knows when a mould remains closed.

The water chiller to cool down the streams of chemicals is housed away from the control room.

By installing a PLC remote I/O board, monitoring and powering up is now done from the comfort of the control room

The Air Pick Up area is a dangerous one. 

To reduce the risk of someone getting access to this area when line is running, gates were installed with switches and stroboscopic lights to warn and  prevent the line from running.

The offline is were the foam seats are trimmed off, inspected and repaired. 

So to automate the conveyering network, a series of photoeyes were place to trigger or stop the advance of  the conveyors.  VFD are set to start and stop in ramp mode so motoreducers life span is mainteined, since the system will start and stop the motors depending on the flow of foam seats.

The Tdi Tank must not be as low as 18°C or else it will become gel.  There is a thermoresistor to measure the ambient T.

Thus, there were blowers with heaters, but they never run.

So all I did was to rewire the control box to the closest PLC rack and then just program a simple hysteresis cycle algorithm.

The compressors and air driers purge water+oil jets.

To avoid making a mess, I built a purge collector than then runs the liquids to the already existing separator.

Using a mechanics vibration probe , a PC mic and a freeware called WINSCOPE...

I was able to plot the vibration spectrum of motor bearings for historical records on preventive maintenance.

To prevent unatorized personnel from using the forklifts, a optical card reader was installed on the units.   Card is inserted and then a button is pressed to start up the engine.