REAL Controls offers our clients a comprehensive group of technical services including:

  • Electrical Design
  • Mechanical Design
  • Automation and Control System Development
  • Software Engineering
  • Machine Design and Fabrication
  • Electrical Panel Design and Fabrication
  • System Integration
  • Project Management

We serve a wide range of clients including commercial, industrial, laboratory and research companies. We provide turnkey products specifically designed to meet the clients’ requirements. We handle all aspects of the project from inception through design, fabrication, installation and commissioning.

Design Tools

Our engineers are skilled with using a wide variety of software design tools including Microsoft Office, Autcad, Inventor, LabVIEW, Allen Bradley, Siemens and Automation Direct PLC programming software. These tools allow us to work efficiently to produce high quality, professional work.

Ice Rink

The electro-mechanical design of the client’s refrigeration electrical system was difficult to maintain, expensive to build, complicated to install and nearly impossible to modify to meet their customer’s requests for customized designs. REAL Controls redesigned the entire electrical system as a PLC based system. The new design required less enclosure space. As a result, we were able to accommodate all of the electrical components into a single enclosure assembly. We also replaced many of the discrete temperature, flow and pressure switches on the refrigeration system with analog sensors in order to provide the equipment operators and maintenance technicians with the information they need to effectively perform their jobs.

Oil Filtering

A client required an automatic control system for a high volume hydraulic oil filtration system for a large machine building operation. The control system needed to function reliably and unattended on a 24 hour, 7 day-per-week basis and needed to include equipment diagnostics and alarms including troubleshooting and maintenance alerts. The system was to be installed outdoors and considerations were needed for the wide range of environmental conditions that this would impose on the hardware. REAL Controls designed, fabricated and installed a PLC based control system using an Automation Direct PLC and touchscreen human-machine interface (HMI). Alert and status messages are displayed on the HMI. The system operates in an automatic mode continually but manual control functions are also provided through the HMI. Alerts are provided when maintenance is required, such as dirty oil filter replacement.

Pill Counter

A manufacturer of automation products for the pharmaceutical industry was experiencing problems with a new product offering that was developed for counting pills to fill pharmacy prescriptions. The company had identified several potential causes for the quality problems but they needed to run a series of experiments to determine the degree that each of these potential issues contributed to the failures. REAL Controls developed a data acquisition and control system to operate the pill counters and acquire data on the performance of the counters for simultaneous tests on multiple counters. The system communications with the counter control system and passes operating commands to the counter from user configurable test sequences. As the sequences are executed by the counter, data is acquired both from sensors that were added to the counters and from sensors already installed on the counters. Some data was acquired using high speed data acquisition cards and other data was acquired using serial communications with the counter.

Wondersaw

Our clients manually controlled chop saw process was slow and prone to human error in cutting the correct lengths of material. REAL Controls automated the process and we developed a program to optimize the amount of material that could be extracted from each board of lumber that was cut. This resulted in maximizing the production yield and insuring that each board was cut accurately to length.