|
We have developed and implemented a software program called “IN HOUSE” by SCADA PIERIPLAST SAC SYSTEM allowing us to monitor the different variables that influence the injection, and metalization paint process.
|
SCADA Technical Description
The SCADA system is composed of:
- 5 PLCs Fatek,
- 1 PLC Glof LG,
- 1 PLC Mitsubishi
- 1 PLC Shihlin,
- 3 HMI Weintek Touch screen ,
- 2 MSI Wind Top Touch screens,
- 1HMI Proface Touch screen and
- 1 HMI Hitech Touch screen.
|
 |
 |
All of these devices (PLCs, HMIs and displays) are integrated into a network through an Industrial HP ProLiant ML115 through RS-485 interfaces and Ethernet with Modbus RTU, Modbus Ethernet and Fatek and Mitsubishi dedicated protocols.
|
|
SCADA system monitoring can be performed on the company intranet and Internet (Remote Access).
|
|
|
INJECTION MONITORING
Equipment Services (engines pumps, Chillers, Cooling Towers, Compressors, Heat Exchangers), and Machine Injection Molding Machines Blowers, they have Hour meters of operating hours. Once completed its working hours (e.g. Weekly, Monthly, Quarterly, Semiannually or annual) the system sends a MAINTENANCE REQUEST and sets the alarm (LIGHT + HORN) audible and visible to alert the maintenance staff.
|
 |
|
Hour Meter PREVENTIVE MAINTENANCE
- 168 Hours WEEKLY
- 720 hours MONTHLY
- 2.160 Hours QUARTERLY
- 4.320 Hours SEMIANNUALLY
- 8.640 Hours ANNUAL
AUTOMATIC FEEDING SUPPLY SYSTEM
This system monitors and controls the raw material supply from 24 Plant Injection machines using an HMI in each one.
|
|
Normal Water System
- Monitors the control status (ON / OFF) from the Normal water pumps and cooling towers.
- Level Control System in Normal water tank.
- Temperature monitoring at the entrance and exit of the heat exchangers in the cooling tower circuit as well as in the machines route.
|
 |
 |
Chilled Water System
- Monitoring the chillers’ state (ON / OFF) and their respective chilled water pumps in the cooling circuit.
- Monitors the control status (ON / OFF) of the Chilled Water Pump in the machines route.
- Temperature monitoring at the entrance and exit of the machines in the chilled water system.
- Monitors pressure from the chilled water lines.
|
|
Pressurized Air System
- Monitors the control status (ON / OFF) of the compressor, dryer and pressure accumulators.
- Pressure Monitoring in Pressurized Air Lines.
- Status Monitoring of Pressure in Pressure Accumulators.
- Temperature Status Monitoring dew on the air dryer.
|
 |
 |
Surlyn Material Temperature
- Monitoring Temperatures of tubs & Cooling Tunnels products Surlyn material.
|
|
Alarm System
- Tank Levels
- Surlyn Material Temperatures
- Temperatures and Pressures
- Equipment
- Computer shutdown
- Equipment overload
- Change Equipment
- Semiannual Maintenance
- Quarterly Maintenance
|
 |
INJECTION MONITORING
The maintenance of the mold is according to the number of injection process (100,000, 150,000, etc.) Having reached this amount, the system generates and sends a MOLD MAINTENANCE REQUEST through an alarm, so that a proper maintenance may be scheduled. The PLC injection process information is accumulated in the Production Monitoring System integrated by SCADA.
The following table shows some molds and their relevant amounts of injection processes after which they are taken for maintenance.
| NUMBER INJECTED |
PRINT |
NAME |
| 150.000 |
CAP FOR FEMALE |
TEMPTATION |
| 100.000 |
OVER CAP FOR AMERICA |
FRAGRANCE |
|
150.000
|
OVER CAPS FOR FIORI |
N/P |
|
75.000
|
OVER CAP FOR MINI BLUE |
INTENSE |
|
100.000
|
BROCHE CASE FOR TANGO |
GRANDE |
|
|
|
Injection cycle
- Monitoring work cycles of injection machines, work status (STOP / STANDARD / LOW STANDARD / OVER STANDARD / NO ORDER PRODUCTION).
- 12 hour shift work cycle report, scheduled hours and rest hours.
PRODUCTION MONITORING
- This system allows us to enter production orders generated in the ERP SOFTWARE SOFTGAP and assign them to a particular machine (Production Order, Mold Installed, Mold Features, Production Quantity and manufacturing standard in 12 hours). This allows us to monitor production and assess Indicators (performance, availability, quality rate) up to the last 8 shifts per machine.
- Production Report on12-hour shifts.
|
METALLIZATION PROCESS MONITORING
- Pumping equipment status (on / off) that includes valves, pumps, and coolant.
- Status Indicator (Open / Close) from the gates of the metallization machine and an alarm if both doors are open.
- Valves operation timer (MM: SS); the complete cycle and the number of cycles the metallization machine has been working per shift.
|
 |
|
- Follow up on the process, displaying the rotational speed at each stage of processing and display of process parameters.
- Lists and charts variables of cycle period from the metallization machine (day and time at which information is stored) with an option to choose information by shift, day or production order.
- Lists errors from the metallization machine through time (day and time at which information is stored) with an option to select by shift, day or production order.
|
|
PRODUCTION MONITORING
- Monitoring of the production variable and its trend over time per shift and by order.
- Initiation and completion of production orders to process
|
 |
|
|
TECHNICAL DESCRIPTION
The SCADA for metallization comprises:
- 1 PLC Fatek FBs-60MCTJ (explicit variables to the SCADA),
- 1 PLC Mitsubishi FX2N-60MR (metalizing machine)
- 2 PLC Shilin AX2N-60MR (paint sequence),
- 2 communication modules 485 FX2N-485BD (485bus),
- 1 communication card FBs-CBE (Ethernet),
- SCADA also has sensors that verify pressure, temperature, amperage and proximity. The system also includes warning lights and a siren.
|
|
COMMUNICATION:
Communication between the CPU, the PLCs and the metallization machine in line 1 and line 2 is accomplished through a 485 bus interface and the Mitsubishi FX protocol, while communication with the PLC is done through Fatek Ethernet and Modbus TCP/IP.
|
 |
|
|
|
|
