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Case Studies

Air Pillow Machine Control

Truly a benchmark of WRD's capabilities, this control was designed, developed and produced in a six-week period.

A typical PLC replacement scenario, the customer needed to lower manufacturing costs, increase functionality, and create ease of field serviceability.  Per unit, raw cost savings were over $250.


Inside the machine "before".


Inside the machine "after".


The "guts" that were replaced.


Total control - power, UI, CPU.


The old user interface.

The new UI.


  Seven (7) optically isolated Inputs plus four (4) keypad inputs -

  • Footswitch start / stop

  • CAM open / close

  • Jam

  • Thermocouple (2)

  Five (5) Outputs plus Backlit LCD

  • Three Motor

  • Two PWM Controlled Heater

          (Two channels of closed-loop temperature control)

  RS232 for diagnostics and in-circuit

  Fault alarm

  Operating voltage: 95 VAC - 130VAC