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CASE STUDY

Mobile Automation Demo Unit

Portable PLC & Ignition HMI Demo Cart for MMEC — Deployed Statewide Across Montana

The Challenge

The Montana Manufacturing Extension Center (MMEC) needed a portable, self-contained automation demonstration unit that could travel to manufacturers across Montana — making industrial automation concepts tangible for plant managers and operators who had never seen a live PLC and SCADA system.

Many small and mid-sized Montana manufacturers were unfamiliar with practical automation options. MMEC needed a hands-on tool that could demonstrate real PLC control, data collection, and HMI operation in a compact, transportable format — without requiring a fixed facility or specialized setup.

The Solution

Logic Control Systems designed and built a portable two-tank fluid automation system mounted on a mobile cart — featuring a PLC, Ignition HMI, VFD-controlled pump, PID control loop, and multiple sensors.

System Components

• A clear Fill Tank (upper position) provides full visibility of fluid movement and level changes — letting observers see the process in real time.
• A Reservoir / Supply Tank (lower position) acts as the fluid source, continuously feeding the system.
• A VFD-controlled pump transfers fluid from the reservoir to the fill tank, with speed modulated by the PLC based on process conditions.
• A proportional ball valve on the drain line controls the discharge from the fill tank back to the reservoir, enabling both batch and continuous modes.
• A load cell measures the weight of fluid in the clear tank, providing the primary process variable for the PID control loop.
• Banner Engineering sensors provide level detection signals to the PLC for low-level shutoff and cycle management.
• An HMI touchscreen and PLC are housed in the control panel, giving operators full visibility and control of the system.

Operating Modes

Batch Mode

The operator enters a target fill weight on the HMI. The PLC runs the pump to fill the clear tank to the target weight, then automatically stops — demonstrating recipe-driven batch control and closed-loop weight feedback.

Continuous Mode

The PLC runs a PID control loop to maintain a target fluid level in the clear tank, continuously modulating pump speed and drain valve position to hold the setpoint — demonstrating real-time process control.

Data Collection

The Ignition HMI logs process data throughout each demonstration — showing manufacturers how production data can be captured, trended, and reviewed without manual recording.

A single portable cart demonstrates PLC control, SCADA data collection, PID loops, and batch automation — giving Montana manufacturers a hands-on look at what modern automation can do for their operations.

Technology at a Glance

Results & Impact

• Increased awareness of practical automation options among small and mid-sized Montana manufacturers.
• Demonstrated that precision batch and continuous control is achievable at any scale — not just in large facilities.
• Provided manufacturers with concrete data collection examples, making the business case for automation more tangible.
• Supported MMEC's broader mission of strengthening Montana manufacturing competitiveness through hands-on technical education.
• Created an ongoing resource that MMEC can deploy across the state at trade events, facility visits, and educational programs.

About Logic Control Systems

Logic Control Systems (LCS) is a Texas-based industrial automation integrator specializing in PLC programming, SCADA/HMI development, process control, electrical panel fabrication, commissioning, and remote automation maintenance. LCS serves clients across the U.S. in industries including food processing, fabrication, chemical, oil and gas, pharmaceutical, and water/wastewater.

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