automated solutions for the extrusion industry …gmceo.co.za/portals/9/aciadms/docs/temp/saveomat...

AUTOMATED SOLUTIONS FOR THE EXTRUSION INDUSTRY

SAVEOMAT M2

Datei: iNOEX-Gravimetrie-saveomat_M2_2_e.ppt Rev.-Datum: 29.07.2005

Folie: 2

The Situation

Case Study

The Components

Weight per meter control via haul-off

Advantages

Automation System SAVEOMAT M2

Optional Features

Details

References


Folie: 3

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!

The situation


Folie: 4

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

The situation - Extrusion without SAVEOMAT


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Same volume but…..

different mass !

The situation: variations in mass throughput


Folie: 6

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

Example:

Pipe extrusion WITH

compensation of mass

throughput variations

The situation - Extrusion with SAVEOMAT

► Start animation

Saveomat_Bulk_density_fluctuations_HD.wmv






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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

Case Study: Pipe extrusion operated by hand


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Mass throughput variations

are recorded and compensated

through adaptation of the

haul-off speed

Varying weight per metre

rates substantially reduced

Tolerances are observed

Automated process: weight per metre control/haul-off

Constant weight per meter

without violation of

tolerances


Folie: 9

Reduced

weight per

metre

Line output

increases

Tolerances

are observed

New working point after weight per metre contr./haul-off

Savings approx.

2-5% (in this case 2,5%)

by red. weight per meter

Constant weight per meter

without violation of

tolerances


Folie: 10

Potential savings

Consumed material kg/h Consumed material kg/year*Material savings 2,5 % in

kg/year

150 750.000 18.750

300 1.500.000 37.500

500 2.500.000 62.500

750 3.750.000 93.750

1000 5.000.000 125.000

1400 7.000.000 175.000

* 5.000 working hours/year


Folie: 11

SAVEOMAT M2 – The Components

Line Speed Encoder Funnel weigher IGS M1

Adapter

Terminal SAVEOMAT M2

with desk top enclosure

Haul-off speed recording

Haul-off speed control

SET-

Value

Mass

throughput

Screw

speed

Mass throughput

recording


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SAVEOMAT M2 –Terminal


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Mounting of weighing

hopper at the load

cell

Weighing hopper

Impact cone and

window for flow

control

Measuring

electronics

Assembly of measuring mechanics


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Advantages: SAVEOMAT IGS mono weigher

Established technique is

integrated

RAS scoop valve

full usability of

inlet cross-section

no angel„s hair


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Optimized mechanical protection of the load cell and the pneumatic parts

Maintenance-free

Overload protection

Advantages: SAVEOMAT IGS mono weigher


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Example: Weight per meter control via haul-off

Weight per metre

kg/m (set value)

Mass throughput

kg/h (real value)

kg/m < set value

kg/m > set value

kg/m = set value

Reduce haul-off speed

m/h

Increase haul-off speed

m/h

Constant haul-off

speed m/h

yes

no

no

Haul-off speed m/h

(real value)

SAVEOMATM2

yes

yes


Folie: 17

kg/hm/hkg/m

Weight per metre control


Folie: 18

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

SAVEOMAT M2 – Haul-off controls weight per metre


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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

Advantages & Benefits

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: 20

Optional: Ethernet Interface M2

Functionality:

1. SAVEOMAT M2 sends

operating data to the Ethernet

interface by interface RS232

2. Production data is sent once

per minute

3. 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

IP

Interface

RS232

Data protocol

1 x per min

Ethernet E.I.


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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)

Optional: Ethernet Interface M2


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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.

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.

Option: Wall-Thickening for pipe sleeves

Important note:

The SAVEOMAT requires an external contact to identify the wall thickening

process.

Wall thickening delay period (Pipe

option)


Folie: 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: 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 V2

---------------------------------- X 0,5 X 100 = Limit in %

Production speed V1


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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.

Change operating point 17.11.03 16:10:15

Act. 10.79 m/min New 0,1 m/min

225.8 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

1

2

3

4

5

6

7

8

Mask: working-point modification


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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.

Printer Parameter 17.11.03 16:10:15

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

1

2

3

4

5

6

7

8

Mask: Printer Protocol


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Option: Printer Protocol

03


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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 6000-7000 Gauß


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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: 30

Option: Rapid material discharge

Adapter with an outlet for rapid material discharge

For installation between funnel weigher IGS M1

and the extruder

Adapter

Rapid material discharge


Folie: 31

Precise interruption of filling procedures

No material flow during measuring cycles

Details: The radial stripping gate


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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

Saveomat_impact cone_HD.wmv





Folie: 33

Actual throughput

0..10 Volt or +/- Signal for RPM

RPMIGS97

Details: Throughput regulation


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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

Reference List SAVEOMAT M2 (Excel)

Referenzliste 2006 Juli.xls

Referenzliste 2006 Juli.xls

Referenzliste_SAVEOMAT M2.xls

Christian MaassArea Sales Manager

iNOEX GmbH

Borweg 27

D-32547 Bad Oeynhausen

Tel.: +49 (0) 57 31- 98 86 - 0

Fax: +49 (0) 57 31 - 9 67 66

[email protected]

www.inoex.de

automated solutions for the extrusion industry …gmceo.co.za/portals/9/aciadms/docs/temp/saveomat...

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