Actually I've been talking to Bo (via email). Initially I was hoping to just help with the code and download via modem, but he really wants somebody on site. He's probably right about that. Seeing it work might be much better.
Bo took the time to carefully lay out a 12 step sequence of events type of discription of how the system is supposed to work. Actually he's got two seperate production units that are setup to operate from one DL130DR.
The current configuration uses all of the 130s I/O. Additionally the welding head is mounted on a swing arm that is to travel in both directions, however it does not allow for the use of a quadature encoder so you get no direction feed back (just a single pulse train). Additionally there is no accomidation for automatic homing. So the operator must set the initial swing-arm position by jogging the unit, then pressing the run button, which will reset the counter and start the unit to welding.
The project is actually rather simple, (possably less then 400 instructions), but I think it would be better served by seperating the two welders to operate from two PLCs. This would allow for quadatrue counting, automatic homing, less operator intervention, future expansion and so on.. Additionally one PLC failure wont result in the loss of production of two welders.
So I'm working on Bo to make a few hardware changes. Even if I cant do that I still might be up for taking a long weekend train ride, do a little programming for Bo, and enjoying the sites, fine dining etc.. with my leading lady.
Mike.