AUTOMATED SOLUTIONS FOR THE EXTRUSION INDUSTRY SAVEOMAT M2

Transcription

1 AUTOMATED SOLUTIONS FOR THE EXTRUSION INDUSTRY SAVEOMAT M2

2 Automation System SAVEOMAT M2 The Situation Case Study The Components Weight per meter control via haul-off Advantages Optional Features Details References Folie: 2

3 The situation Unstable raw material lots lead to variations in the extrusion process affect conformity to product recipes influence quality and efficiency of the production process A constant, reproducible extrusion process is decisive for an economic production process! Folie: 3

4 The situation - Extrusion without SAVEOMAT Raw material is subject to varying bulk density granule shape flowability Irregular mass throughput Restricted control options Example: pipe extrusion without compensation of mass throughput variations Folie: 4

5 The situation: variations in mass throughput Same volume but.. different mass! Folie: 5

6 The situation - Extrusion with SAVEOMAT Raw material is subject to bulk density variations But: Mass throughput variations are recorded and automatically compensated Constant weight per metre Improved product quality Material savings of an average 2-5 % Integrable into every extrusion line Start animation Example: Pipe extrusion WITH compensation of mass throughput variations Folie: 6

7 Case Study: Pipe extrusion operated by hand Mass throughput variations are neither measured nor controlled Set weight per metre is 855 g/m Still, tolerances are shortly exceeded or dimensions fall below set limits Folie: 7

8 Automated process: weight per metre control/haul-off Mass throughput variations are recorded and compensated through adaptation of the haul-off speed Varying weight per metre rates substantially reduced Tolerances are observed Constant weight per meter without violation of tolerances Folie: 8

9 New working point after weight per metre contr./haul-off Reduced weight per metre Line output increases Tolerances are observed Constant weight per meter without violation of tolerances Savings approx. 2-5% (in this case 2,5%) by red. weight per meter Folie: 9

10 Potential savings Consumed material kg/h Consumed material kg/year* Material savings 2,5 % in kg/year * working hours/year Folie: 10

11 SAVEOMAT M2 The Components Line Speed Encoder Terminal SAVEOMAT M2 with desk top enclosure Funnel weigher IGS M1 Adapter Haul-off speed recording SET- Value Mass throughput recording Screw speed Mass throughput Haul-off speed control Folie: 11

12 SAVEOMAT M2 Terminal Folie: 12

13 Assembly of measuring mechanics Mounting of weighing hopper at the load cell Weighing hopper Measuring electronics Impact cone and window for flow control Folie: 13

14 Advantages: SAVEOMAT IGS mono weigher Established technique is integrated RAS scoop valve full usability of inlet cross-section no angel s hair Folie: 14

15 Advantages: SAVEOMAT IGS mono weigher Optimized mechanical protection of the load cell and the pneumatic parts Maintenance-free Overload protection Folie: 15

16 Example: Weight per meter control via haul-off Weight per metre kg/m (set value) Mass throughput kg/h (real value) SAVEOMATM2 kg/m < set value no kg/m > set value no kg/m = set value yes yes yes Haul-off speed m/h (real value) Reduce haul-off speed m/h Increase haul-off speed m/h Constant haul-off speed m/h Folie: 16

17 Weight per metre control kg/m m/h kg/h Folie: 17

18 SAVEOMAT M2 Haul-off controls weight per metre Application: Extrusion of pipes, profiles, film and cables Production process run at maximum extruder speed Increase in line speed for higher output Process: Control concept for compensation of mass throughput variations through adaptation of haul-off speed Resulting is a constant weight per metre Folie: 18

19 Advantages & Benefits Improvement in quality Reduction of weight per metre to an absolute minimum Increase in productivity Production data (kg/h, kg/m, etc.) Reduction of start-up scrap Production is constant and reproducible due to constant weight per metre Material savings up to 3,5 % due to constant quality Increase in production due to reduction of weight per metre Documentation of production data Cost reduction up to 70 % due to early flawless production Folie: 19

20 Optional: Ethernet Interface M2 Functionality: Ethernet IP E.I. Data protocol 1 x per min 1. SAVEOMAT M2 sends operating data to the Ethernet interface by interface RS Production data is sent once per minute Interface RS Data is stored in a Linux data file and can be retrieved through an adjustable IP address. Production data is available as time or length controlled data Folie: 20

21 Optional: Ethernet Interface M2 Ethernet Interface M2 consists of: Data collection and storage for coupling to SAVEOMAT M2 (IDC, no.2799) Software module TCP/IP for data transmission TCP/IP (no. 2768) Production data is stored on this hardware and can be retrieved as file (Linux) through an IP address Optional: Desktop PC (without monitor), IDM (Intelligent Data Management), operating system Windows XP (no. 2764) Data collection module IDS software (no. 2778), intermediate data storage upon selection (e.g. fault reports, process data) of data previously stored on the SAVEOMAT system, data reading by one of these systems, data storage/ filing on a server. Data retrieved through IP address Data visualization module IDV software for visualization of recorded data in chronological order or of process data in a trends graphics (no. 2779) Folie: 21

22 Option: Wall-Thickening for pipe sleeves When the line speed is decreased for wall thickening, the SAVEOMAT is given a signal. The controller switches from Automatic to "Stand By, to prevent the controller from compensating the higher weight per metre of the thicker wall section. Wall thickening delay period (Pipe option) To prevent the controller from being activated again too soon after the wall thickening is accomplished, (time point t 3), a "wall thickening delay period is set. This period permits the SAVEOMAT to keep the controller in "Stand By" mode until speed V 1 is reached. When the wall thickening has been accomplished, the controller switches back to Automatic, the SAVEOMAT now displays the original haul-off speed and controls the weight per metre. Important note: The SAVEOMAT requires an external contact to identify the wall thickening process. Folie: 22

23 Option: Coil change recognition Coil change recognition does not require an external contact, the SAVEOMAT identifies upcoming coil changes automatically. Identification is based on a constant comparison of hauf-off speed rates. The base are 3 mean values (MW) of the haul-off speed: MW 1 = is the longest mean value, taken for speed measurement in constant automatic operation, comparatively slow acting due to its length MW 2 = is a short mean value which is calculated from the last measured values, very quickly identifies any changes. MW 3 = is also a short and fast mean value, however, it is taken at the end of the value recording. The SAVEOMAT identifies a reduction in production speed V1 to the coil change speed V2, because MW 2 is now 25 % lower than MW 3. SAVEOMAT switches the controller to Stand By. Folie: 23

24 Option: Coil change recognition The coil change speed V 2 has been reached, the controller remains in " Stand By " mode. The line is brought to production speed V 1 again. Mean values MW 1, MW 2 and MW 3 match, SAVEOMAT switches the controller back to normal automatic operation. Important note: The specific function coil change" does not require an external contact. Identification is automatically done through a comparison of haul-off speed rates. A setting in per cent of the limits Coil change recognition" is recommended, given approx. 50% of the speed difference: Coil change speed V X 0,5 X 100 = Limit in % Production speed V1 Folie: 24

25 Option: Working Point Modification The optional working point modification equipps SAVEOMAT with the hardware and software required to select a second motor potentiometer There are two options to change the operating or work point of an extrusion line: 1. A new haul-off speed is displayed as a default value. SAVEOMAT then calculates the required throughput capacity for the extruder. 2. Enter a new throughput capacity for the extruder. SAVEOMAT then calculates the required haul-off speed. Once the function has been started, SAVEOMAT will move both drives to their new operating point by a ramp function. This is done synchronously, so that the weight per metre of a product remains nearly constant even during this period. As soon as the process has been completed, the SAVEOMAT controller resumes its work Mask: working-point modification Change operating point :10:15 Act m/min New 0,1 m/min kg/h 0,1 kg/h Ramptime 0 min Ramp On = 1 0 Rest time 0 sec Status: AUTO Error Line 1: Mask Identifikation with current time and date Line 3: Display of current haul-off speed and entry of a new one Line 4: Display of current mass throughput and entry of a new one Line 5: Entry of ramp time Line 6: Release of ramp function Line 7: Display of the remaining ramp time Line 8: Status line, display of the operating mode with error information Folie: 25

26 Option: Printer Protocol The printer option equipps SAVEOMAT with the required hardware and software. The interface is an RS 232. Data is transferred as a sequence of bits. Length or time controlled print out: The print-out is triggered when a pre-set length or time is reached. Externally triggered print-out: The print-out can be triggered by an external contact, e.g. for coil changes. Error printout: Activation of this feature prints out errors, including date and time. Selection of printer protocol, protocol 0: Printer protocol 0 will always be printed with the header. The size is half a DIN A4 page Mask: Printer Protocol Printer Parameter :10:15 Time interval: 0 min 0 Length Interval: 0 m 0 External Trigger: 0 Error Protocol: 0 Protocol no.: 0 Status: AUTO ERROR Line 1: Mask Identifikation with current time and date Line 3: Setting the print-out interval, release of the time dependent print-out Line 4:Setting the length interval for the print-out, release of the length dependent print-out Line 5: Release of the externally triggered print-out Line 6: Release of the error print-out Line 7: Section of the printer protocol Line 8: Status line, display of the operating mode, error information Folie: 26

27 Option: Printer Protocol 03 Folie: 27

28 Option: Magnetic Grid / Separator Magnetic grid for separating magnetic impurities (iron particles) 2-3 magnetic bars separate the finest iron impurities from the bulk material. The magnetic bars are mounted on a removable grid and can be taken out without any special tools easy cleaning. It is made for dry, free flowing granules up to a granule size of 6 mm and up to a temperature of 80 C, non-moving or slowly flowing material columns Installation: between funnel weigher IGS M1 and extruder (s. photo) Magnetic field strength Gauß Folie: 28

29 Option: Adapter with inlet for purge material Adapter with side inlet for purge material and a rapid material discharge For installation between funnel weigher IGS M1 and extruder Adapter Folie: 29

30 Option: Rapid material discharge Adapter with an outlet for rapid material discharge For installation between funnel weigher IGS M1 and the extruder Rapid material discharge Adapter Folie: 30

31 Details: The radial stripping gate Precise interruption of filling procedures No material flow during measuring cycles Folie: 31

32 Details: The impact cone Serves material decoupling Avoids material columns on the dosing unit or the extruder screw Basic condition to measure the material weight in the weighing hopper Start animation Folie: 32

33 Details: Throughput regulation Actual throughput IGS97 RPM Volt or +/- Signal for RPM Folie: 33

34 Reference List SAVEOMAT M2 (Excel) Many customers world-wide have installed our system SAVEOMAT M2. Click to see the complete chart, options to filter data, e.g. as per countries, customers or delivery dates Folie: 34

35 Christian Maass Area Sales Manager inoex GmbH Borweg 27 D Bad Oeynhausen Tel.: +49 (0) Fax: +49 (0)