Let me give you some examples of how this guy thinks:
1.) Spends $5000 on a custom stainless steel water header pipes and fittings for this welder. Can't use the DM because of cost issues.
2.) Installs a 2 channel estop system and instead of putting the reset on the operator console he puts it on the control cabinet, one that you have to walk around the entire machine to access when it has wire loaded in it to weld.
3.) Puts a second LOGO unit in the operators console just to act as a counter... with a display screen that after six months can't control when the machine cuts.
4.) Speaking of automatic shearing of mesh sheets... Finally he gets the counter section of the program working. He can't get the shear to cut via the plc but he can make a light flash on the control panel letting you know that you need to manually push a button marked "Cut".
5.) The machine is fed from 480vac 850amp supply. The 24vdc control power supply was fed from an extension cord through the wall to an outlet on the other side of the bay. 15 times the whole machine shut off due to someone unplugging the cord... All the while there is a 480-120 transformer about 2ft under the power supply in the cabinet.
6.) Added 12 or so new 22mm lights to control panel, and when I asked what they were for he told me, "Nothing now, but don't worry I'll find use for them"
This machine had 15 relays inside, and it only used 4 of them. The wiring prints fit neatly on a 11x17 page. Now there are 30+ relays, 2 LOGO units, 2 small HMI screens, and about half of it works.
Yeah, that's what our new sister plant does.
