Titus automation / electrical
Project
Portfolio
Titus automation / electrical
Project
Portfolio
Project
Portfolio
Chilled Water System
Voestalpine – Chilled Water System
- Utilising Schneider TM221 PLC and IO
- Schneider 7” HMI screen for the controls of the system and Siemens variable speed
- Soft starts to drive the various pumps for the system
Project summary :
There are two separate chilled water systems, both with fail safe duty cycles. This ensures that, if one system fails, the other system will start automatically thereby guaranteeing no downtime in the factory.
The system ensures a reliable supply of chilled water to machines by controlling the chiller and cooling towers. A variable speed drive feeds the circulation system to maintain the desired pressure. All settings for the control system are entered onto an HMI screen and the PLC system performs the necessary controls.
Client Details
Voestalpine
Service Provided
Chilled Water System
Project Year
2019
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Client Details
Voestalpine
Service Provided
Chilled Water System
Project Year
2019
Titus Consulting : Company Profile
Download Titus Consulting’s company profile to learn about our mission, goals, vision, and company history.
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
2 x 250kVAR Power Factor Correction Panels
Polytec – 2 x 250kVAR Power Factor Correction Panels
- Rittal panel and busbar
- Schneider switchgear
- Schneider capacitors
- Schneider VARPlus controller
Project summary :
Client Details
Polytec
Service Provided
2 x 250kVAR Power Factor Correction Panels
Project Year
2019
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Client Details
Polytec
Service Provided
2 x 250kVAR Power Factor Correction Panels
Project Year
2019
Titus Consulting : Company Profile
Download Titus Consulting’s company profile to learn about our mission, goals, vision, and company history.
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Clicking Press Revamp for Daimler W206 project
Feltex Trim – Clicking Press Revamp for Daimler W206 project.
- Replaced existing switchgear with Siemens switchgear
- Upgraded PLC to Siemens S7-1200 PLC with ET200S
- Installed new Siemens KTP 7” HMI
Project summary :
Client Details
Feltex Trim
Service Provided
Clicking Press Revamp
Project Year
2020
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Client Details
Feltex Trim
Service Provided
Clicking Press Revamp
Project Year
2020
Titus Consulting : Company Profile
Download Titus Consulting’s company profile to learn about our mission, goals, vision, and company history.
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Factory Power Reticulation
Polytec – Factory Power Reticulation
- Installed wireways for machinery supplies
- Installed main cables for machinery supplies
- Manufactured and installed sub-DBs
Project summary :
Client Details
Polytec
Service Provided
Factory Power Reticulation
Project Year
2020
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Client Details
Polytec
Service Provided
Factory Power Reticulation
Project Year
2020
Titus Consulting : Company Profile
Download Titus Consulting’s company profile to learn about our mission, goals, vision, and company history.
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Wheel Arch Heater Platen for Daimler W206 project
Feltex Trim – Wheel Arch Heater Platen for Daimler W206 project
- Revamped Heater Platen Press
- Installed Rittal floor standing enclosure
- Replaced existing switchgear with Siemens switchgear
- Upgraded PLC to Siemens S7-1200 PLC with ET200S
Project summary :
Client Details
Feltex Trim
Service Provided
Wheel Arch Heater Platen
Project Year
2021
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Client Details
Feltex Trim
Service Provided
Wheel Arch Heater Platen
Project Year
2021
Titus Consulting : Company Profile
Download Titus Consulting’s company profile to learn about our mission, goals, vision, and company history.
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Portable Heater Element Testing Panel
Polytec – Portable Heater Element Testing Panel
- Delta DTK temperature controllers and Celduck Solid State Relays for temperature control
- Harting plugs
Project summary :
Client Details
Polytec
Service Provided
Portable Heater Element Testing Panel
Project Year
2022
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Client Details
Polytec
Service Provided
Portable Heater Element Testing Panel
Project Year
2022
Titus Consulting : Company Profile
Download Titus Consulting’s company profile to learn about our mission, goals, vision, and company history.
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
1250A LV Distribution Board
Dukathole – 1250A LV Distribution Board
- Utilising copper busbars for mains power distribution through the DB
- Flexible busbars/welding cable to the breakers
- ABB switchgear
- ABB power meter installed to view various parameters relating to the main supply
Project summary :
Client Details
Dukathole
Service Provided
1250A LV Distribution Board
Project Year
2022
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Client Details
Dukathole
Service Provided
1250A LV Distribution Board
Project Year
2022
Titus Consulting : Company Profile
Download Titus Consulting’s company profile to learn about our mission, goals, vision, and company history.
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Automatic Infeed Adhesive Spray Booth
IAC – Lamination Carpet Pulling Gantry Control Upgrade
- Manufactured a Contact Adhesive Spray Booth with automated tool infeed and tool coding
- Installed a Rittal floor standing enclosure
- Siemens S7-1200 and KTP900 Basic HMI were used to control the system and integrate with the Robot
- Supplied and installed a Fanuc EX Rated P-40iA Robot for controlled spraying
- Festo VPPM pressure regulators were installed for the adjustment of spray patterns and volume of glue application.
- A Festo DGC 1.5m Pneumatic Linear drive was installed to control the automated infeed with chain linked, overlapping infeed tables
- Airotech Devilbiss Spray Gun was mounted at the end of the Robot for controlled application of the contact adhesive
Project summary :
We designed and manufactured an Automatic Infeed Adhesive Spray Booth for the automated adhesive glue application onto BMW G45 headliner frames, Mercedes W206 headliner frames and Mercedes W206 headliner clip and stiffener components.
Swappable tools were created to fit onto the automated overlapping infeed tables, allowing for loading of new parts whilst parts are being sprayed.
The two tables were each split in half, allowing for the use of either one large or two small tools on each table. This allows for up to 4 different products to be run at once. This model can store up to 15 variants with recipes configurable via the HMI.
In partnership with Puchs Engineering (mechanical manufacturing) and Invent Engineering (mechanical design)
Client Details
IAC (International Automotive Components)
Service Provided
Adhesive Spray Booth
Project Year
2024
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Client Details
IAC (International Automotive Components)
Service Provided
Adhesive Spray Booth
Project Year
2023 -2024
Titus Consulting : Company Profile
Download Titus Consulting’s company profile to learn about our mission, goals, vision, and company history.
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Lamination Carpet Pulling Upgrade
IAC – Lamination Carpet Pulling Gantry Control Upgrade
- Installed Festo Motion Control PLC
- Swapped out existing single Siemens Drive controlled motor for horizontal control with two Festo CMMT Drives and 2 EMMT Motors
- Changed the two existing Festo CMMT Profinet Drives with two CMMT Ethercat drives to interface with the Festo Motion Control PLC
- Modified existing system to utilise improved motion control and added quality of life features to improve client usability
Project summary :
Upgraded an existing gantry system for the automated pulling of the headliner carpet material. Utilising a Festo motion control PLC and Festo drives, the pulling system was upgraded to improve the gantry’s movement for smoother operation and improved cycle times.
At 60% of the programmed maximum speed, the cycle time for each carpet pull was improved from ±28 seconds to ±14 seconds, allowing for improvements in part production speeds.
The improved motion control also reduces wear and tear on the mechanical systems, as there are fewer stop/starts and greater control over acceleration and deceleration, reducing maintenance requirements.
Quality of life was also improved by moving the HMI and control switches next to the press HMI instead of where it was on the opposite side of the machine.
Manual jog buttons were also interfaced into from the existing press as they were redundant.
This allows for easier operation by the operator and maintenance staff reducing downtime.
In partnership with Puchs Engineering (Mechanical Modifications) and Invent Engineering (Mechanical Design)
Client Details
IAC (International Automotive Components)
Service Provided
Lamination Pulling Upgrade
Project Year
2024
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Client Details
IAC (International Automotive Components)
Service Provided
Lamination Pulling Upgrade
Project Year
2024
Titus Consulting : Company Profile
Download Titus Consulting’s company profile to learn about our mission, goals, vision, and company history.
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
825kVA Standby Generator Installation
825kVA Generator, Changeover Board & Soft Starters
- Installed Power Analyser for two weeks to gather sufficient information on load profile of the installation to calculate the size of the generator required.
- Investigated load profile of each crusher and selected the correct brand and size soft starter to start the crushers and reduce the startup loads.
- Designed a new building and ventilation for the generator and control room.
- Additional fans were added into the control room and control panel to improve ventilation.
- Power factor controller is switched off when generator is running.
- Installed new wireways and cables for the installation. 2 x 300mm single core cables per phase and neutral were installed in trefoil between generator and new changeover board.
- Rittal floor mounted changeover panel was installed with ABB breakers and changeover switch.
Project summary :
Installation of 825kVA Standby and 750kVA Prime Baudouin Generator for Independent Crusher’s B-Plant which is housed in a ventilated building to protect the generator from the harsh environment it was installed in, thereby increasing its life span. Ventilation included the installation of a duct on the outlet side of the generator and filters on the inlet.
The generator was installed with a standalone 1250A changeover board which included an ABB 1250A automatic transfer switch and 2 x 1250A air circuit breakers for the protection of the incoming Eskom supply and the outgoing supply to the main control panel.
Existing star-delta circuits controlling the 3 crushers on the plant were replaced with ABB soft starters to reduce the maximum load to allow the generator to start the plant. The corresponding switchgear and control gears were also upgraded. The retrofitting of the soft starters on the crushers reduced the startup load by around 500A, reducing the customers maximum demand as well as allowing the generator to start the plant.
In partnership with ACS (Air Conditioning Services)
Client Details
Independent Crushers
Service Provided
Alternative Power Supply
Project Year
2023 - 2024
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Client Details
Independent Crushers
Service Provided
Alternative Power Supply
Project Year
2023 - 2024
Titus Consulting : Company Profile
Download Titus Consulting’s company profile to learn about our mission, goals, vision, and company history.
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
G45 Independent Operator Checking Gauges
TI Automotive – G45 Independent Operator Checking Gauge Fixtures
- Modified manual fixtures and installed Automated Checking Gauges for critical points along the pipes
- Utilised Rittal Compact Enclosure for electrical systems
- Utilised Siemens S7-1200 and KTP700 Basic HMI for system control
- Utilised Festo Pneumatics and Cylinders for controlling clamps and paint markers
- Utilised IFM AL Profinet remote IO modules and IO Link enabled KG Capacitive Sensors for high accuracy and configurable raw capacitance value feedback
- Designed and manufactured Checking Gauge clamps and Paint Marking application system
Project summary :
Modified existing manual checking fixtures and installed an automated, operator independent critical point gauge checking system with OK/NOK, nondestructive, paint marking system for passed and failed part identification. By utilising IFM KG Capacitive sensors with IO link, the raw capacitance value could be read back from the sensor, allowing for greater accuracy when identifying part tolerances. Tolerance setpoints can be configured for each sensor via the HMI for greater control over part testing and prevent unauthorised individuals from adjusting the settings. A fingerprint scanner was incorporated to enforce supervisor intervention in the event of a NOK part, preventing NOK parts from being supplied to the client.
In partnership with Puchs Engineering (mechanical manufacturing) and Invent Engineering (mechanical design)
Client Details
TI Automotive Pretoria
Service Provided
Automated Pipe Checking Gauges
Project Year
2023 - 2024
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Client Details
TI Automotive Pretoria
Service Provided
Automated Pipe Checking Gauges
Project Year
2023 - 2024
Titus Consulting : Company Profile
Download Titus Consulting’s company profile to learn about our mission, goals, vision, and company history.
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Changeover Panel
Voestalpine – 1600A Changeover Panel
- Manufactured changeover and marshalling panel
- Utilised ABB 1600A 4P manual changeover switch and 1250A 3P moulded case circuit breaker for the Eskom supply to inverter panels
Project summary :
Manufactured an enclosure for the changeover switch which allowed the client to change over between Inverter and Eskom supply and a breaker for Eskom supply to the inverters.
An additional marshalling enclosure was manufactured and installed for the connection of inverter supply to changeover.
Modified existing Distribution Board and busbar work. Installed 3 x 300mm2 single core cables per phase as the incoming supply to the panel from the existing Distribution Board and busbars linking from the changeover switch back to load busbars in existing DB.
Client Details
Voestalpine
Service Provided
1600A Changeover Panel
Project Year
2023
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
Client Details
Voestalpine
Service Provided
1600A Changeover Panel
Project Year
2023
Titus Consulting : Company Profile
Download Titus Consulting’s company profile to learn about our mission, goals, vision, and company history.
OUR PROJECTS
- 250kVAR Power Factor Correction Panels
- Clicking Press Revamp
- Factory Power Reticulation
- Wheel Arch Heater Platen
- Portable Heater Element Testing Panel
- 1250A LV Distribution Board
- Automatic Infeed Adhesive Spray Booth
- Lamination Carpet Pulling Upgrade
- 825kVA Standby Generator Installation
- G45 Independent Operator Checking Gauges
- Changeover Panel
