SAVEOMAT. The next dimension of gravimetric mass throughput control

Transcription

1 SAVEOMAT The next dimension of gravimetric mass throughput control

2 2 SAVEOMAT SAVEOMAT 3 SAVEOMAT RECIPE FOR PROFITS: MASS INSTEAD OF VOLUME. SAVEOMAT product line stands for gravimetric systems for the perfect conveyance of raw material. The system records variations in mass throughput rates and keeps values at a stable level. As such, SAVEOMAT makes sure that process values, i.e. weight per length, wall thickness and the product recipe itself are identical to set values. Same volume, but... SAVEOMAT systems operate with an exceptional precision, they feature a state-ofthe-art command system and operation is easy. Its hardware and software were specifically designed for any kind of extrusion process and they have undergone a continuous development over the past 30 years, particularly thanks to the good cooperation with our customers and renowned extruder manufacturers....different mass! "More than 700 SAVEOMAT installations per year are convincing evidence of the acceptance and efficiency of these systems in global markets. Miguel Izquierdo Blanco Director Sales and Customer Relations Measure: Mass throughput Weight per length Haul-off speed Control: Weight per length by extruder / dosing screw Weight per length by haul-off unit Mass throughput by extruder / dosing screw Wall thickening function Coil change recognition Working point changes Guide parameter controller Bleeding Volume is not identical to mass this principle captures in a nutshell what the demands on modern gravimetric systems are all about. inoex has therefore decided for the material weight as the unit of measure. For 30 years, the gravimetric extruder control and/or haul-off control have been the base of automation of extrusion lines. Automatic Mode Manual Operation Extruder Output Automatic Mode set value Reduced weight per length Haul-Off Speed Loss in Weight guarantees the accurate throughput assessment in per cent, independent of the bulk density. Especially for co-extrusion lines, no other control principle is conceivable for layer thickness control. Weight per length Mechanical and electronical parts are finely tuned to each other for a precise and intelligent dosing process of all material components. Retrofitting becomes easy thanks to the modular design of all electronic components. Filling First measuring cycle; dynamic weight measurement by load cell Bottom filling level of approx. 20 % triggers refill Start of new measuring cycle

3 4 SAVEOMAT SAVEOMAT 5 THE NEXT DIMENSION OF GRAVIMETRIC DOSING MONO WEIGHER MONO WEIGHER US MONO WEIGHER HF DOSING STATION I-LINE LIQUID DOSING SATELLITE SAVEOMAT mono weighers for granules and powder are mounted directly above the extruder inlet. A SAVEOMAT terminal controls the screw speed and/or the haul-off speed, depending on the control loop. The production process is kept on a constant level, with exact mass throughput rates, exact weight per length and a reduced consumption of raw material. Reduced raw material consumption! SAVEOMAT US features a gravimetric system of different sizes with funnel weighers for the non-obstructed addition of powder into the extrusion process. Raw materials including a max. weight ratio of 20 % of chalk (CaCO 3 ) can be dosed by this weigher. Non-obstructed dosing of max. 20 % CaCO 3! SAVEOMAT HF is a series of gravimetric systems with funnel weighers for the addition of hardly flowing materials. Max. weight proportion of chalk: 100 % (CaCO 3 ). Dosing of up to 100 % CaCO 3! SAVEOMAT i-line is a freely configurable flexible dosing station for the accurate mixing and dosing of max. 7 components. Suitable for granules or powder. Custom-made dosing stations for complex applications! SAVEOMAT MD allows the continuous dosing and conveyance of granules, powder and liquid materials such as peroxide or silane. Strict adherence to recipes during the dosing and conveyance process. The accurate supply and control of the multi-component dosing station reduces consumed material quantities, particularly the consumption of peroxide or silane. Multi-component dosing! SATELLITE conveys materials to single extrusion lines or complete production halls through one or more vacuum generators switched in parallel. Depending on mass throughput rates, the number of extrusion lines and the kind of raw material, different series are available. All of them will create an economical solution. Innovative valve technology for an optimum vacuum distribution!

4 6 SAVEOMAT modular automation system SAVEOMAT modular automation system inoex automation module igs with command and control unit, sensor system and digitized motor control STATE-OF-THE ART MEASURING TO ACHIEVE THE HIGHEST CONTROL ACCURACY! ADVANTAGES OF MULTI-RANGE SCREWS: Working ranges of inoex funnel weighers tuned to conveying rates 90 % of all applications or materials do not require any screw changes SELF-OPTIMIZATION. Multi-range screws The igs electronics unit developed by inoex is self-optimizing. The measuring electronics adapts to each material component and re-optimizes this process independently during each measuring cycle. The latest dosing motors with large speed ranges and torques make screw changes superfluous. Sophisticated control algorithms permit the conveyance of tiny volumes of material directly on top of the extrusion line. CONVINCING INNOVATIONS: 24 bit A/D converter High-resolution rotational speed recording Easy integration by way of a VNC-Server Status messages for each component on a 7-segment display 32 bit command by micro-controller SAVEOMAT switch cabinet Software updates by Ethernet or USB Screw types Throughput ranges r.p.m. Designation No. Color 0 white Screw Sleeve Ø [mm] Ø [mm] RAL color [kg/h] yellow light green violet brown blue red sand turquoise green Modular design 10 silver Integration by Profibus DP, Profinet, Ethernet, CANopen 11 khaki dove blue

5 8 SAVEOMAT mono weighers SAVEOMAT mono weighers 9 SAVEOMAT: REDUCED MATERIAL USAGE! TECHNICAL DESIGN: FUNNEL WEIGHER. The funnel weighers of the SAVEOMAT line are mounted directly on top of the extruder opening respectively the starved feeding screw. Depending on the control loop, recorded measuring values are used either for screw speed control or haul-off speed control. As a result, the production process is kept on a constant level, with accurate mass throughput rates or weight per length values. Plus, raw material usage is reduced to a minimum. SAVEOMAT funnel weigher sizes: Type Mass throughputs [kg/h] Height [mm] (granules) Storage hopper Capacity l / height [mm] TW / 375 TW / 375 TW / 375 TW / 635 TW / 635 TW / 845 TW / 845 TW / 1215 TW on request TW on request TW on request PRODUCE AT A PROFIT WITH SAVEOMAT: Stable and reproducible processes based on constant mass throughputs or weight per length Control of up to 2 components in mono or co-extrusion, simultaneous haul-off control Suitable for granules and powder Weight per length reduced to a minimum Output increased by up to 5 % Raw material savings of up to 5 % Reduced start-up scrap Increased line capacity USER-FRIENDLY OPERATION. Command of the funnel weigher is either integrated into the extruder control unit or it is implemented into a SAVEOMAT operation terminal. The terminal has a touch screen. MEASURE / CONTROL / EVALUATE WITH SAVEOMAT 5 UND SAVEOMAT 10: Two (SAVEOMAT 10) or one (SAVEOMAT 5) control loop(s): SAVEOMAT mono weigher for granules TECHNICAL FEATURES IN SHORT: Perfect funnel geometry for an excellent material flow behaviour Quick release of the weigher hopper Transparent weigher outlet for visual flow control Filling without dead zones Overload protection of the load cells Integrated cable routing Different sizes available for throughputs from 0.2 to 2,000 kg/h (0.44 to 4,400 lb/h) Weight per length by haul-off Weight per length by extruder/dosing screw Mass throughput by extruder/dosing screw Options: Wall thickening function Coil change recognition Ramping Manual adjustment Magnetic separator Addition of a close-down batch Rapid material discharge Printer protocols (SAVEOMAT 10) SPC functions (SAVEOMAT 10) History trend (SAVEOMAT 10) SAVEOMAT 5 and SAVEOMAT 10 terminals

6 10 SAVEOMAT powder weighers SAVEOMAT powder weighers 11 RELIABLE POWDER DOSING. USE SAVEOMAT US OR SAVEOMAT HF. BENEFITS SAVEOMAT US: Optimized funnel geometry for an optimum flow behaviour for PVC with a proportion of approx. 20 % CaCO 3 Quick release of the weigher hopper Filling without dead zones Overload protection for load cells Integrated cable routing Control either integrated into extruder control or by SAVEOMAT terminal SAVEOMAT HF IN SHORT: Co-rotating twin screw dosing unit Agitator directly above the screw infeed zone and the load cell Overload protection for load cells Storage hopper with robust agitator Screws designed for chalk, PVC, wood Control either integrated into extruder control or by SAVEOMAT terminal Type Height [mm] / [inch] Mass throughputs [kg/h] / [lb/h] SAVEOMAT 750 US 940 / / SAVEOMAT 1000 US 955/ / SAVEOMAT 1400 US 1070/ / SAVEOMAT 1600 US 1130/ / SAVEOMAT 1800 US 1190/ / SAVEOMAT 2000 US 1250/ / SAVEOMAT 2500 US 1395/ / Type Volume [l] / [cu. ft.] Mass throughputs [kg/h] / [lb/h] SAVEOMAT 350 HF 80 / / SAVEOMAT 500 HF 80 / / SAVEOMAT 750 HF 80 / / SAVEOMAT 1000 HF 120 / / SAVEOMAT 1400 HF 120 / / SAVEOMAT 2000 HF 250 / / SMOOTH PROCESSING OF MAX. 20 % OF CHALK (CACO 3 ) Do you process chalk? TW US has been specifically designed for the addition of chalk with a maximum weight proportion of 20 %. The SAVEOMAT US powder weigher prevents material deposits or blockages. An enlarged radial strip-off device (RAS) and a larger inlet further ensure that the dosing process is not obstructed. If the flow of material is slightly disturbed, turbine vibrators mounted on the weigher inlet and on the outlet of the storage hopper start acting. Conclusion: TW US funnel weighers not only ensure that a production process may run smoothly but also that quality standards are achieved! NO LIMITS TO MATERIAL MIXTURES: SAVEOMAT HF. No restrictions in chalk ratios with this innovative high-filler system which eliminates all variations in material feeding from the start. So far, continuously operating gravimetric systems could only handle chalk proportions of up to 20 %. Moreover, a continuous material flow could not be guaranteed. Higher ratios frequently led to the building of material bridges because powders act like they want. SAVEOMAT HF is the answer. It features a double-screw dosing unit and two active mixing units. The vertical mixer in the conical weigher hopper prevents the formation of bridges and the double screw conveyor plus the z-shaped mixer ensure a regular material feeding. These are perfect conditions for the continuous and the regular dosing of powders or chalk. On account of strongly varying powder feed rates, the measuring and control frequency of SAVEOMAT HF weighers compared to standard weighers is substantially higher. All PVC-mixtures with a chalk proportion of up to 100 % can be accurately dosed.

7 12 SAVEOMAT i-line SAVEOMAT i-line 13 SAVEOMAT i-line for granules available in these sizes: Main components Throughputs [kg/h] Side components Throughputs [kg/h] HK NK HK NK HK NK HK NK HK NK USER-FRIENDLY INTERFACE. The control unit is either integrated into the extruder control or into the SAVEOMAT operation terminal with a multi-touch screen. User guidance by an intuitive user interface. All recorded data is automatically documented. It can be perfectly used as quality evidence or to optimize recipes and product quality. HK NK HK NK HK HK HK CUSTOMIZED DOSING STATIONS FOR DEMANDING TASKS! PRECISE PRODUCTION ALONG COMPLEX RECIPES. SAVEOMAT i-line series represents freely configurable, flexible dosing stations designed for the accurate blending and dosing of up to seven material components. Each dosing process is specifically adapted to the customer s requirements. And we have the flexibility to address special colour requirements. For powders and granules. DOSING STATION SAVEOMAT I-LINE. The dosing station is positioned on top of the extruder. Up to 7 material components, i.e. 1 main component and up to 6 side components are conveyed to the infeed zone of the screw. Each component has got its own dosing unit. Based on the recorded measuring data, the command unit activates the control loops with all corresponding parameters. As a result, the production process is kept constant which includes mass throughput rates. Plus, raw material consumption is kept to a minimum. MEASUREMENT / CONTROL / EVALUATION MODULES: Weight per length by extruder/dosing screw Printer protocols Weight per length by haul-off unit Magnetic separator Mass throughput by extruder/dosing screw Addition of a close-down batch Wall thickening function Rapid material discharge Coil change recognition Start-up program for film Ramping SQL data transfer Processing of external ramps Recipe scanner Bleeding function Multi-touch Guide parameter control Freely configurable interface (design, Widgets Tablet-, Smartphone- access Multi-access in parallel SAVEOMAT 20 and SAVEOMAT 15 terminals SAVEOMAT i-line

8 14 SAVEOMAT i-line SAVEOMAT i-line 15 SAVEOMAT i-line AS INDIVIDUAL AS YOUR APPLICATIONS. FEATURES: Customized configurations possible Main component TW Up to 7 components (1 MC (main component) + 6 SC (side components)) Side components TW For complex recipes and specific applications Available for granules and powder For mono-extrusion, co-extrusion, coex dosing Specific colours available SAVEOMAT HF component Material decoupling for linear, synchronized measuring value recording Standard dosing unit for SC , medium size dosing unit for SC 500, large dosing unit and additional collar piece for SC 750 und SC 1000 FREELY CONFIGURABLE AND INDIVIDUAL. With SAVEOMAT i-line there are almost no more limits. Up to 7 components can be dosed. The flexible combination also allows for customized solutions such as the 6 component dosing station without a main component. INCREASED FLEXIBILITY AND EFFICIENCY. Due to the enormous variety of materials, it becomes increasingly difficult for the raw material industry to maintain a profitable production while having to respond to the wide range of their customer s needs. At the same time order quantities become smaller. Besides, producers face the problem of having to comply with their customer s wishes to supply new and frequently changing products within very short delays. Material recipes required to this end can be ordered readily mixed or as single components which are then composed to recipes. Ready compounds may not be profitable due to minimum quantity surcharges. Additionally, short-term changes in the composition may be possible only to a limited extent. Dynamic mixer with double screw dosing unit Material processing directly on top of the extruder offers a higher flexibility. However, there remains the necessity to adhere strictly to the recipe. This means that all components need to be added in their exact set quantities. For powder and chalk dosing such as e.g. in PVC foam pipe extrusion, this is a particularly complex process. For this purpose, inoex has developed the SAVEOMAT HF differential dosing system for the gravimetric dosing of any kind of chalk, coated or uncoated. Custom-built: SAVEOMAT i-line dosing station without main component

9 16 SAVEOMAT MD SAVEOMAT MD 17 MULTI-COMPONENT DOSING OF PEROXIDE OR SILANE! EFFICIENT MEASUREMENT, CONVEYANCE AND BLENDING. Particularly in the PEX-a and PEX-b pipe and cable extrusion, product quality strongly depends on the accurate and controlled dosing of all components. SAVEOMAT IGS MD6 is designed for the perfect dosing of all solid and liquid components. SAVEOMAT MD components: MC SC Liquid SC l/h l/h l/h l/h l/h l/h Main components, side components and liquid side components can be freely varied Silane injection COMBINED STATIC AND DYNAMIC BLENDING. SAVEOMAT IGS MD6 features both static and dynamic blending techniques. The static blender merges all solid components and spreads the main component to prepare for all side components to flow in. In the second blending stage, a dynamic blender ensures that the material mix is entirely homogeneous. Directly on top of the extruder, either peroxide is added by a capillary tube or silane is injected through an injection nozzle attached inside the dynamic blender. Like this, peroxide or silane are evenly sprayed on the flowing granules. FEATURES: Continuous dosing and conveyance of granules, power, peroxide/silane, conforming to recipes Accurate and homogeneous blending of all raw materials Constant cross-linking degrees Self-optimization of recipes, definition of unique product features No pre-blending time, more flexible production planning Cost-efficient raw material purchase due to individual recipes Capillary tube for peroxide injection SAFETY TECHNOLOGY: Overflow container for leakage. In case a tube is defective, the leaking liquid is directly led into the collecting tank Sensor in the collecting tank releases an alarm Sensor for leakage control in explosion-proof design Measurement and monitoring of the protective gas Side components can be completely switched off by a butterfly valve Leakage control from the feeding room to the dosing station Peroxide conveyor station: fully automated conveyance of peroxide according to ATEX 95 EC safety regulations Feeding Room: storage of peroxide conveyor station Storage Room Side components and the main component have individual measuring cycles Highly accurate spinning pump ensures liquid conveyance Spinning conveyance chambers and servomotors allow the precise conveyance of smallest quantities Liquid side component, incl. pump and dosing motor, filter block, injection nozzle and nitrogen gas injection Max. 3 liquid components Peroxide proportion reduced by approx. 10 % due to homogeneous blending of raw material Silane storage hopper: storage of 2 silane barrels of 200 l each close to the production site

10 18 SATELLITE SATELLITE 19 FEATURES: High-capacity vacuum generators for complete extrusion halls reduce costs Vacuum generators switched in parallel for a fail-safe operation and capacity reserves Innovative vacuum distribution for the simultaneous filling of several components Constant vacuum for shorter conveyance periods Blow-out of the macro filter Modular concept for individual solutions Integrated control unit based on SAVEOMAT For PE, PP and PVC granules INNOVATIVE VALVE TECHNOLOGY FOR A PER- FECTLY DISTRIBUTED VACUUM! SMOOTH CONVEYANCE OF RAW MATERIALS. The smooth conveyance of raw materials is a key element for an efficient production process. A potential for value creation lies hidden here. SAVEOMAT SATELLITE suction conveyance by ino- EX addresses both aspects: a profit from a higher cost-efficiency because conveying processes are optimized and at the same time a reduction in energy- and maintenance costs. ECONOMIC CONFIGURATION BASED ON CENTRAL VACUUM GENERATION. The proven de-centralized suction valve technology permits to change air cross-sections by way of which the conveying speed can be adapted to individual parameters such as the conveyance route, the conveyed volume and the conveyed material. This way an individual vacuum can be generated for each material separator. CONCLUSION. SAVEOMAT SATELLITE is able to generate a vacuum for complete extrusion lines or even complete production halls via single vacuum generators or several vacuum generators switched in parallel. Depending on the mass throughputs, the number of lines and the different raw materials, specific system types are on offer to create an economical solution. FOCUS: VACUUM DISTRIBUTOR AND MATERIAL SEPARATOR. The valve technology is the key element of SAVEOMAT SATELLITE suction conveyance. A perfected distribution technique distributes the available suction capacity to all material separators. The suction capacity corresponds to recipes and requirements and it is adjusted to each component. Each material separator is equipped with a macro filter which divides the aspirated material into granules and dust. At the end of a conveyance cycle, air expansion is used for the self-cleaning of the macro filter. INNOVATIVE FEATURES: Suction capacity can be divided as needed Simultaneous conveyance by several material separators Vacuum instantly available Shorter conveying cycles Material bottlenecks prevented Less vacuum generators required Reduced material and energy costs Self-cleaning of the macro filter SAVEOMAT i-line with SATELLITE

11 20 Process visualization IDM, inotrend 21 VISUALIZATION CONCEPT. The cross-platform concept headed for the future permits the visualization as a Website by way of an easy integration through a browser. This way the inoex user interface can be visualized on all systems, which are Internet enabled. The multi-touch surface permits an intuitive operation by gesture command (zoom, swipe). Operation is carried out through installed Widgets, which can be freely configured by the user, independent of their size or information, they can be added or removed as required. This allows the user to have permanent access to the most important applications (favorites). FAST CUSTOMER SUPPORT WITH TEAMVIEWER. Worldwide support via remote control Easy configuration, no VPN gateways In accordance with the highest safety standards IDM - THE INOEX DATA MANAGER. IDM for the centralized recording of the process and quality data of all extrusion lines. The analysis and the creation of reports are carried out by the integrated inotrend function. Secure data storage via RAID in a SQL database. Access to all relevant production data via SQL database Database server and centralized data storage, NAS (Network Attached Storage) Visualization + data evaluation via inotrend INOTREND. With the software option inotrend production data and process values can be recorded and visualized in diagrams. The displayed process data and time periods can be individually configured by the user. Besides the pre-defined diagrams individual configurations are possible with the user-friendly software. inotrend further offers the option to generate and file reports. Protocols can be stored in common formats such as PDF or.csv-data files for Excel. Data can then be exported by USB stick, e.g. for documentation by the customer. Operation of inotrend is intuitive via multitouch screen on the terminal. Alternatively, the software can be accessed through a web browser.

12 22 Payback Payback 23 YOUR PROFITS. Your profit is measurable. SAVEOMAT systems allow enormous material and cost savings. Payback periods of sometimes only a few months lead to a fast amortization of a SAVEO- MAT system. SAVEOMAT MONO WEIGHER Manual Operation Automatic Mode Automatic Mode set value Reduced weight per length Output Production time Savings Material costs Savings p.a. Extruder Output 1000 kg/h 16 hrs/day x 350 days/year 3 % 1.30 /kg 218,400 SAVEOMAT i-line (3 COMPONENTS) Haul-Off Speed Output Production time Savings Material costs Savings p.a. 800 kg/h 16 hrs/day x 350 days/year 3 % 1.30 /kg 174, kg/h 16 hrs/day x 350 days/year 3 % 1.30 /kg 54, kg/h 16 hrs/day x 350 days/year 3 % 3.00 /kg 25, ,520 Weight per length SAVEOMAT MD Output Production time Savings Material costs Savings p.a. 250 kg/h 16 hrs/day x 350 days/year 3 % 1.40 /kg 58, kg/h 16 hrs/day x 350 days/year 3 % 6.20 /kg 13,020 5 kg/h 16 hrs/day x 350 days/yearr 3 % /kg 20,160 91,980

13 GERMANY inoex GmbH Phone: Fax: GREAT BRITAIN inoex Office UK Phone: Fax: TURKEY inoex Office Turkey Phone: Fax: CHINA inoex LTD. Phone: Fax: USA inoex LLC Phone: Fax: inoex GmbH All rights reserved. Reproduction in total or in parts without explicit written approval by the copyright owner is prohibited. inoex GmbH reserves the right to change a product or to terminate its production at any time without prior announcement and without any obligation. Errors or technical changes excepted. Status: September info@inoex.de