AQCnet: the software package for POLAB laboratory automation. ThyssenKrupp Industrial Solutions. Our new name is. tk Polysius

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1 Our new name is ThyssenKrupp Industrial Solutions AQCnet: the software package for POLAB laboratory automation tk Polysius

2 2 AQCnet The software for quality assurance and control AQCnet Advanced Quality Control is the sophisticated ThyssenKrupp Polysius software for POLAB laboratory automation. It thus forms the intelligent basis for reliable and highperformance product quality control. AQCnet Highlights AQCnet performs convincingly in all systems: from the simple laboratory right up to complex laboratory automation systems with automatic samplers, pneumatic tube system, automatic sample preparation system and quality control. The configurable interfaces permit integration of online analysers and a broad range of laboratory devices. AQCnet connects the proven POLAB control algorithms with state-of-the-art network technology and a comfortable operator interface. Browser-based operator interface Client-server structure.net technology with Web interface SQL base Standardised interfaces with analysers Configurable reports and trends Priority-controlled sample processing Adaptive mixture control Password-protected access Multiple language user guidance Online help function Remote maintenance The graphic operator interface gives access to the essential AQCnet functions: AQCnet controls and monitors the automatic starting of sampling actions, sample conveyance to the laboratory, sample preparation and sample analysis. The integral sample tracking facility shows the processing status of all active samples. Current system messages are displayed in a message window. A base with adaptable filter functions assures specifically directed evaluation of system messages.

3 3 Database and log generation User General Confi guration SQL base Process Laboratory Evaluation and archiving of measurement The combination records of the analysers and the quality controllers are allocated to the respective sample and stored in an SQL base. AQCnet consolidates these measurement records to a unique sample record. It is possible for the user to calculate derived measured variables, such as lime standard, silica modulus and alumina modulus, according to predefined equations or to specify userspecific equations. The measurement and the derived measured variables of the sample are relayed to the control algorithms of the integral quality controller. It is also possible to export to other computer systems via an OPC interface or with the aid of files in XML or CSV format. Log generation AQCnet supports the generation of user-specific reports for outputting measurement and derived measured variables. These reports can be generated, displayed and printedout on a cyclic basis. For this purpose, AQCnet provides functions for statistical evaluation (minimum, maximum, quantity, mean value, variation, sum, sum x2 and standard deviation) and for colour-marking limit value violations. In addition to output in list form, it is possible to output as trend graphs and a combination of list and trend graph. Combination of list and trend graph.

4 4 Administration, operation, remote maintenance Administration AQCnet provides system administration functions with a clearly arranged web-based operator interface. These functions include: n setting up password-protected user accounts whose logon authorisations can be individually specified, n graphic definition of types of material with the associated sample processing parameters, n modification and extension of the POLAB system and n definition of event-controlled and cyclic operations such sample starting, issuing of reports, export and backup. Operation and diagnosis The AQCnet software includes system-wide machine operation and diagnosis. The latest-generation POLAB machines are equipped with networkable operator panels. The operator interface of every local operator panel can be called up on every operator workstation of the POLAB computer system. This facilitates not only the system-wide operation and diagnosis, but also enables efficient remote maintenance. Bedienoberfläche eines maschinennahen Operator interface of a Bedienfeldes: local operator panel: Intuitives Arbeiten durch intuitive working using Touchscreen und grafische touch screen and graphic Bedienoberfläche. operator interface. POLAB computer system VPN or Modem connection ThyssenKrupp Polysius service Remote maintenance For remote maintenance the POLAB computer system can be linked through to Polysius Service via a secure Internet connection or a telephone connection. Upon request, qualified specialists support the plant personnel during the system optimisation and modification measures. Here, compliance with the required safety standards naturally has absolute priority.

5 5 Control Input Output Quality controller for mixture control The adaptive controller for mixture calculation of raw material, raw meal and cement adjusts the ratio of the material components to match the mixture of the specified quality setpoints. It reduces disturbing influences such as material fluctuations, weigher inaccuracies, etc. An adaptation algorithm continuously assesses the chemical composition of the individual material components and accordingly adjusts the controller. The selected command variables can be cement moduli like the lime standard (LST), silica modulus (SM) or alumina modulus (TM) or oxides (e.g. Al 2, SiO 2, S ) or other user-defined variables. Control loop for mixture control of raw meal and cement This control loop can be used as silo control for controlling the silo contents or as sample control for controlling the individual samples. Used as silo control, it can be configured for continuous blending or batch blending. Control loop for separator control The AQCnet separator control assesses the deviation of the measured material fineness from the setpoint value and accordingly adjusts the separator speed. Control loop for mixture control of blending bed Used for blending bed stacking control, the adaptive controller can be configured for circular blending beds or longitudinal blending beds.

6 6 Blending bed software Blending bed visualisation and reclaiming forecast for circular blending beds The blending bed visualisation of the AQCnet software provides a graphic representation of the raw material in the circular blending bed. The chemical composition of the raw material is indicated with the help of different colours. The user can select a graphic representation for the stacked layers or a graphic representation for the layers to be reclaimed. A table or a trend diagram shows the precalculated concentration of selected chemical elements depending on the reclaimer position. Al 2 Reclaiming zone Stacking zone 8 % 4 % 3 % 0 % Graphic display of stacked layers. Al 2 8 % 4 % 3 % 0 % Graphic display of layers to be reclaimed. Al 2 [%] [ ] Current reclaimer position Selected angle Selected angular range for calculating average values Trend diagram and table with precalculated concentrations of selected chemical elements depending on the reclaimer position. Scraper Current Next Stacking zone Selected Zone Angle AI2O3 CaO Fe2O3 H2O K2O Mn2O3 MgO Na2O SiO2 SO3 TiO2

7 AQCnet At a glance 7 Basic Operating system Visualisation Maximum expanded configuration MS Windows XP, Windows 7, MS Server 2003, MS Server 2008 WEB user interface, Internet Explorer 4 automatic laboratory devices in joint operation Data export Configurable exports into text files (XML, CSV for Excel imports), Configurable loading onto OPC2 process signal values that can be read by external systems Data evaluation 20 plant-side automatic devices 3 samplers per plant-side automatic device Statistical Formula min., max., number, mean value, variance, sum, sum X 2, standard deviation formula library and user-defined formulae 10 manual plant-side devices with 99 selectable types of material Logs 3 additional manual receivers in the laboratory Output Web browser 3 I/O magazines per automatic laboratory device Printout time-controlled, event-controlled and manual 4 XRF spectrometers Definition Log editor 4 XRD diffractometers Trends 3 laser granulometers Scaling automatically/manually 3 colorimeters Curves per trend max. 8 2 CO 2 /S analysers Diagrams x/t, real time, history Further options on request Data archiving Sample measurement 5 years Control loop measurement 3 months Messages / alarms 6 months. Larger archives on request Mixture control Algorithm Number of control loops (mills) No. of components per control loop Operating mode linear optimisation with adjustment of the raw material composition max. 16 max. 8 silo control or sample control Sample cycle variable