D&D was hired by Central Process Engineering to complete work on the Chrysler Windsor Assembly Plant paint shop conveyors for the RU launch. D&D’s responsibility was to provide complete turn-key electrical design and controls for the conveyors in a robotic sealer line.
The project kicked off at the end of November 2014. Electrical design started immediately, and continued until April 2015. D&D mobilized and was present on the jobsite from late February until August. Chrysler’s planned 12 week shutdown began in February and production began again in May. D&D had to be adaptable to incorporate several design changes in the sealer area mid-design including splitting the friction drive control into two PLCs. D&D later eliminated other controllers entirely and relocated the conveyor control into the process PLCs. A repair spur was added to the IP&F design late in the project. Due to several mechanical delays, D&D’s commissioning time was severely compressed. In spite of this, all required functionality was working in time for the start of production. D&D modified 7 separate existing drawing packages, and created 2 from scratch. D&D upgraded 2 existing PLC5 programs into GuardLogix and integrated many new pieces of equipment.
Chrysler’s E-coat fork transfers have been upgraded to modern control systems to eliminate legacy equipment. Program structure and addressing has been maintained so that maintenance does not have to re-learn the equipment. The safeties have been brought up to modern standards. The integration of new code into existing PLCs required significant coordination that provided a unique challenge.
D&D was able to successfully complete a significant amount of work in a very short amount of time with a small team of dedicated people.
Teamwork paid off again with another successful project.