BD Automation Service and Solution

For the last two months, we faced an RPM fluctuation issue in the EXTR.B Plast Control System (Germany) of our LLDPE film-making machine. During this period, we carried out extensive troubleshooting and systematically checked every possible point to identify the root cause.

Our troubleshooting activities included:
✅ Checking all cables and connection points
✅ Inspecting and interchanging PCB boards
✅ Testing the IOC and IOX control boards
✅ Verifying load cells and related control systems
✅ Replacing components one by one for comparison and verification.

Despite all these efforts, the problem remained unresolved. We then procured and installed a new load cell, expecting the issue to be eliminated. However, the RPM fluctuation became even more severe.
After ruling out all other possibilities, we considered that the newly supplied load cell itself might be defective. To verify this assumption, we replaced it with another load cell. Immediately, the machine returned to normal operation and the RPM became stable.

This experience reinforced an important lesson: a new spare part is not always guaranteed to be fault-free. Even brand-new components should be thoroughly tested and verified during the troubleshooting process.

Finally, we successfully identified the root cause and resolved the issue. Special thanks to everyone who provided online technical support, guidance, and cooperation throughout this challenging journey.

Every problem is an opportunity to learn. Persistence, teamwork, and systematic troubleshooting are the keys to success. 💪🔧

Recently worked on a Damper actuator (BELIMO SMQ24A-MF) in a BOBST printing machine Rs 6002C where I faced challenges with setting the zero position.

By carefully following the manual guidelines and performing proper adaptation, I was able to successfully calibrate the actuator. After completing the adjustment, the system returned to stable and normal operation.

This experience reinforced an important lesson: persistence and a structured approach to troubleshooting always pay off.

Today, we successfully completed a team training session focused on Industrial Automation & Troubleshooting.

The session emphasized practical approaches to identifying faults quickly—how to detect problematic parts, trace root causes efficiently, and minimize downtime by ensuring faster parts availability from the store.

We also had in-depth discussions on PLC hardware and industrial relays, including the application of NO (Normally Open) and NC (Normally Closed) contacts in real scenarios.
A productive and insightful session that will definitely enhance our team's troubleshooting capability and operational efficiency.

New experience

Today I faced a challenging situation while working on a FATEK PLC programming task. ⚙️💻

After detailed analysis, monitoring the PLC signals, and checking the machine control logic, I was able to successfully complete the troubleshooting and bring the system back to normal operation.
In the engineering field, no task is truly easy, and every problem teaches us something new. Continuous learning, patience, and dedication are the keys to solving complex technical issues.
Alhamdulillah, the issue has been resolved successfully.
—

আজ আমাদের টিমের সাথে একটি PLC Basic Training সেশন পরিচালনা করেছি। ⚙️📚

এই ট্রেনিংয়ের মূল উদ্দেশ্য ছিল টিমের সদস্যদের PLC (Programmable Logic Controller)-এর মৌলিক বিষয়গুলো সম্পর্কে পরিষ্কার ধারণা দেওয়া, যাতে তারা মেশিন অপারেশন ও ট্রাবলশুটিং আরও দক্ষতার সাথে করতে পারে।

ট্রেনিংয়ে আমরা PLC-এর গুরুত্বপূর্ণ অংশগুলো নিয়ে বিস্তারিত আলোচনা করেছি, যেমন:

🔹 Power Supply: PLC সিস্টেমে সঠিক ভোল্টেজ সরবরাহ নিশ্চিত করে, যা পুরো কন্ট্রোল সিস্টেম চালু রাখতে গুরুত্বপূর্ণ ভূমিকা রাখে।
🔹 CPU (Central Processing Unit): PLC-এর মূল প্রসেসিং ইউনিট, যেখানে প্রোগ্রাম এক্সিকিউট হয় এবং ইনপুট অনুযায়ী আউটপুট নিয়ন্ত্রণ করা হয়।
🔹 Digital Input: বিভিন্ন সেন্সর, সুইচ বা ফিল্ড ডিভাইস থেকে ON/OFF সিগন্যাল PLC-তে প্রবেশ করে।
🔹 Digital Output: PLC থেকে মেশিনের বিভিন্ন ডিভাইস যেমন Contactor, Relay, Solenoid Valve ইত্যাদি নিয়ন্ত্রণ করা হয়।
🔹 Analog Input: সেন্সর থেকে আসা Continuous Signal PLC-তে গ্রহণ করা হয়, যেমন Temperature (PT100/PT1000, Thermocouple), Pressure Transducer, Level Sensor ইত্যাদি।
🔹 Analog Output: PLC থেকে বিভিন্ন কন্ট্রোল ডিভাইসে Continuous Signal পাঠানো হয়, যেমন Inverter Speed Control, PID Control Valve, Pneumatic Regulator Control।

এই ধরনের বেসিক জ্ঞান থাকলে ইঞ্জিনিয়ার ও টেকনিশিয়ানরা দ্রুত সমস্যা শনাক্ত করতে পারে এবং মেশিনের downtime কমাতে গুরুত্বপূর্ণ ভূমিকা রাখতে পারে।

টিমের সবার সক্রিয় অংশগ্রহণ সত্যিই প্রশংসনীয় ছিল। 🤝
Knowledge sharing is the key to building a strong and skilled team. 🚀

Successfully completed installation and commissioning of the BST EKR CLS Pro 600 register control system on our printing line at Akij Printing & Packaging Ltd.

This was a critical integration due to compatibility and signal-matching challenges with the existing machine. Through detailed parameter alignment, wiring verification, and calibration, we successfully recovered the system, which is now running smoothly in production.

Proud to be part of the engineering and maintenance team driving reliability and automation improvement.