IMPERIO GCS IMPERIO GCS

IMPERIO GCS
THE SOFTWARE FOR HIGHEST QUALITY AND ECONOMIC EFFICIENCY
IMPERIO GCS
PROCESS AUTOMATION SYSTEM FOR THE GALVANIC PLATING
OF WIRES AND STRIPS IN CONTINUOUS LINE PLANTS
01
02
PAYOFF
03
AEOX
04
GCS
05
AEOX
TAKEUP
IMPERIO GCS
PROCESS
IMPERIO
11
WWTP
10
Energy
09
Supply
08
ABACS
07
LAB
06
INDEX: 01. Payoff 02. Patenting 03. Plating 04. Diffusion 05. Take-Up 06. Laboratory 07. ABACS 08. DEMIN Water Supply 09. Energy Supply 10. Wastewater Treatment 11. Operator Terminal
AUTOMATIC BATH ANALYSIS
AND BATH MAINTENANCE
ABACS. The Automatic Bath Analysis
and Control System
This online analysis and dosing system has been developed by CPA to compactly connect your laboratory
directly with the production process. The fully automatic bath analysis, control and dosing ensures a constant
electrolyte composition and, as an IMPERIO GCS module, is key to ensure a high product quality.
DOCUMENT AND
ANALYZE YOUR
LABORATORY SAMPLES
with IMPERIO GCS
LAB. The laboratory analysis module
If online process data which has been collected by IMPERIO GCS is complemented by offline measurement
data, then this data should be fed into the system and
consequently made available for the automatic adaptation of the plant. The laboratory module enables the
measured sample values to be attributed to the batches.
If enough samples are available, the article parameters
are subsequently adapted based on statistic procedures
(control cards) to further improve quality. The results can
also be used for product documentation in the form of
test certificates for the customer.
IMPERIO GCS
Process Automation System for the galvanic
plating of wires and strips in continuous
line plants
IMPERIO
IMPERIO the process management software by CPA has
been developed to control, supervise and administrate
galvanic coating processes in parallel continuous line
plants, e.g. for brass plating in steel cord production.
This process control system is fully configurable and
parameterizable and, as such, can be used for numerous
processes. Among other functions, IMPERIO GCS is
able to monitor, visualize, automate and optimize CPA’s
galvanic plating units CELLRAC and GALVOMODUL.
The advantages of CPA’s galvanic coating units,
combined with IMPERIO’s efficient control technology,
lead to improved product quality, whilst reducing
the overall process costs and increasing operation
management safety:
Greater precision and constant coating processes:
• less scrap
• reduced energy costs
• reduced electrolyte consumption
• minimized water consumption
• less manpower requirements
IMPERIO GCS is a sector-specific system geared
towards the monitoring and control of the entire galvanic
production process of continuous line plants, including
related functions such as energy supply, media supply
or waste water disposal. As a comprehensive solution to
customers´ requirements, IMPERIO GCS is structured
in terms of functions and distributed to the relevant
computer systems within the individual sections. It is on
these computers that the system is operated on site.
Thanks to configuration, parameterization and
continuous programming, IMPERIO GCS can be fully
adapted to your process.
IMPERIO GCS
IMPERIO GCS SOFTWARE MODULES
MANAGE YOUR ENTIRE PRODUCTION
Always up-to-date with IMPERIO GCS
SUPERVISION. The control room module
with IMPERIO GCS
MES. The manufacturing execution module
The supervision computer has been designed to monitor
the entire plant from the central control room. It gathers
information from the various applications and computers
in order to provide the operator in the control center with
the best possible overview of the process. The manmachine interface (MMI) can be tailored to the specific
needs of the plant in question and designed ergonomically by means of dynamic plant graphics and graphic
automation objects (CPA Power Objects). IMPERIO
GCS starts working once the order for production has
been placed, by extracting the order from the production planning and control module of the ERP (Enterprise
Resource Planning) system. For production orders and
recipes, universally configurable and parameterizable
interfaces, databases and servers are used. If no connection to the ERP system is possible or desired, the
customer‘s orders and recipes are directly dispatched
to IMPERIO GCS and, if needed, scheduled using the
integrated detailed planning module, SCHED. Once the
data has been planned, it is transferred to the MES (Manufacturing Execution System), the executing module,
so that it can launch orders and set up process parameters. Orders are processed during operation and upon
order completion, reports are are produced and statistic
process controls (SPC) are generated based on laboratory and online process data.
The IMPERIO GCS MES component closes the information chain between the detailed planning or the ERP
system and the production process. The MES provides
order-relevant data at the process level and to the ma-
chine. It automatically uses specified data (recipes) from
the order, e.g. article data or product specifications such
as layer weight or coating thickness, in order to avoid
setting errors resulting in reject products.
ANALYZE YOUR PAST AND FUTURE PROCESS DEVELOPMENT
with IMPERIO GCS
SPC. The statistic module
SCHEDULE YOUR PRODUCTION DATES
AT SHOP FLOOR LEVEL
with IMPERIO GCS
SCHED. The planning module
In order to increase planning efficiency and improve the
processing of production orders, data from a previous
detailed planning control center can be transferred to IMPERIO GCS. During this process, specified data such as
dates, times and quantities are extracted and compared
to real-time feedback pertaining to work progress, production quantities and downtime, so that the planning
can be promptly corrected if necessary. This allows reacting at an early stage to avoid delivery problems.
In order to document and improve the process quality,
the IMPERIO GCS process data collection is followed by
a statistic analysis. The statistic module collects all process-relevant data in real time and presents them e.g.
in the form of up-to-date control cards. This enables the
operator to react quickly to quality problems. In addition
to the online process data, test data from material tests
such as wire diameter, strength or results of chemical
analyses or consumption rates can be analyzed. All the
results can be assigned as quality documentation of either the orders or the batches.
IMPERIO GCS
PRECISE DOCUMENTING OF YOUR PROCESSES
THE INTEGRATION OF YOUR ENTIRE PROCESS STARTS
using IMPERIO GCS
REPORT. The documentation module
with IMPERIO GCS
PAYOFF. The payoff module
IMPERIO GCS offers different standardized reports enabling production performance to be documented. These
include an overview of the current plant utilization with
articles and their specifications, as well as produced
quantities expressed as the number of spools, length
and weight. Moreover, the number of incidents, voltage
and current abnormalities, split-up processes etc. pertaining to each plating cell are recorded. All reports can be
optionally generated to give details regarding shift, day,
month, quarter, year or other customer defined periods.
INCREASE THE OPERATIONAL AVAILABILITY OF YOUR
PLANT AND SUPPORT YOUR MAINTENANCE PERSONNEL
The PLC (Programmable Logic Controller) of every single payoff unit is connected to the payoff station via a bus
system. The payoff module monitors all payoff processes and displays their status, e.g. dancer position, bra-
king power, spool change or failures such as wire ruptures or exceeded change times. Here, operation mode,
braking force (if operated manually), control parameters
etc. can be adjusted.
AEOX ENERGY MANAGEMENT
The heat treatment module
using IMPERIO GCS
MAINT. The maintenance module
Via the process control system, the IMPERIO GCS
maintenance module collects the operating hours and
the operating cycles of the unit to be maintained and
supplies the operating personnel with instructions in the
form of daily printed maintenance lists. When doing so,
the module creates advance warnings, based on critical
levels that can be chosen as desired, so that materials
necessary for maintenance can be ordered or personnel
can be scheduled in time. However, periodical maintenance work can be handled as well. The completion of
maintenance work is confirmed within the system and
the work that has been carried out is documented in the
maintenance logbook.
CPA has risen to the challenges of the future - with AEOX
Industrial Furnaces it has developed a revolutionary, cutting-edge heat treatment technology including heat recuperation for steel wire production. These energy-efficient
and combustion-optimized furnaces are fully adapted to
IMPERIO GCS’s general concept of integrally managing
energy and minimizing plant operating costs. Combined
with AEOX, the energy-efficient heat treatment system
and the CPA plating lines, IMPERIO GCS achieves sensational optimization levels with regards to energy, costs
and quality. What’s more, IMPERIO GCS can extract and
monitor the process data from external systems, provided that they are equipped with the necessary standard
interfaces.
IMPERIO GCS
MANAGE YOUR PLANT WITH IMPERIO GCS
PRO. The plating process management module
• The GCS PRO module controls the following
process sections:
- Quenching after heat treatment
- Pickling
- Polishing, if necessary
- Flushing and drying
- Galvanic coating
- Post-processing
Every process section has recirculation, temperature
regulation, filter, dosing and top-up systems. Moreover,
the entire pickling and galvanic power supply has to be
controlled, monitored and coordinated in order to ensure
a constant current density.
Driven contact rolls are synchronized with the wire speed
that is determined by the take-up units. In case of differing
wire speed, the speed of the majority of wires with the
same speed is deemed to be the relevant speed.
• In general, all fluid tanks feature redundant pump
systems with all necessary safety requirements:
- Monitoring of levels, temperature and pumps
- Periodical pump change
- Automatic change in case of failure
- Dry running protection
Filter systems are used to clean the electrolytes and the
pickling media. These need to be maintained and backflushed depending on their contamination.
The bath temperature and the temperature of the pickling
and cleaning media are heated or cooled by means of
partly cascaded heat exchangers. GCS PRO supervises
and monitors the necessary process elements in the
framework of an integral energy optimization system.
Due to evaporation and the continuous drag-out of
pickling and coating media, a regular dosing of water
and stock solution using an automatic top-up program is
necessary. With regard to pickling, an automatic ground
and floating sludge exhaustion is also carried out, with
the removed volume being fed into the receiver tank.
IMPERIO GCS
PUT YOUR QUALITY ON
SOLID GROUND
with IMPERIO GCS
MELPICK. The pickling unit module
Power control relating to the current number of wires and
including voltage monitoring, failure documentation and
temperature-dependent adaptation is carried out with
regard to a high-quality pickling process in a multi-level
electrolyte pickling plant.
THE IMPERIO GCS
MANAGER
IMPERIO GCS Manager.
You decide the recipe of your
desired final product
The GCS Manager is responsible for precise coating
processes. Given that it is easy to use and that
adjustments can be made quickly in the form of articlebased recipes, it efficiently prevents operating and
product errors. The necessary currents and current
densities based on article specifications such as coating
thickness, minimum layer weight or alloy composition
are calculated automatically.
Cell failure compensation
Monitoring and automatic adaption
If adequate coating cannot be guaranteed due to physical circumstances such as cell short circuits, a lack of
anode material, shortfalls in ion concentration or equipment failure, this will be compensated by automatically
splitting up the current to neighboring cells, or, if necessary, by reducing take-up speed. In case of wire break,
the effected power supply modules are turned off for
safety reasons and will be turned back on automatically
after threading in order to ensure that they become productive again as soon as possible.
In order to run the plant with the lowest possible level
of personnel resources, on-site monitoring of the plating
cells is supported by indicator lamps or large displays.
Based on the plating analysis data entered in the laboratory station or via online measuring and testing devices
and their statistical analysis, an automatic adaption of
the article parameters can be generated.
IMPERIO GCS
ALL’S WELL
THAT ENDS WELL
CARING FOR THE
ENVIRONMENT
with IMPERIO GCS
TAKEUP. The take-up module
with IMPERIO GCS
WWTP. The waste water treatment module
Well-functioning, fully integrated take-up units are a prerequisite for smooth galvanic coating processes. The
PLC of every take-up unit is connected to the take-up
station via a bus system. The take-up module monitors
all take-ups and displays their status, such as speed,
spool filling degree, spool change or disruptions such as
wire fracture, excess temperature, frequency converter
or drive failure. Also, here the speed for start and production, starting ramp, wire tension, meter pre-selection,
etc. can be chosen.
An already existing waste water treatment unit can also
be connected and controlled using IMPERIO GCS. The
purification and neutralization of waste water can be
carried out either continuously or in batches (batch process), which are controlled, monitored and documented
by the system. However, manual control measurements
that might be necessary can also be included. Usually,
the generated records have to be handed over to the
respective authority as evidence of correct operation
management. IMPERIO GCS WWTP fulfils this task to
perfection.
CLEAN IS OFTEN
NOT CLEAN ENOUGH
water regeneration as an integral part
of your galvanic coating process controlled and monitored by IMPERIO GCS
DWTP. The water processing module
To process tap water, softening or DEMIN water treatment units with ion changers or reverse osmosis are
mainly used and are often back-flushed, cleaned, regenerated and dosed in batch mode operation. Similarly,
recirculation systems are used for water economization,
which recycle the flushing water and feed it back into
the process system. All water treatment processes for
cost-effective supply of the necessary process fluids are
monitored, controlled and supervised by IMPERIO GCS.
FULLY AUTOMATIC BATH
PREPARATION AND BATH
MAINTENANCE BASED
ON A RECIPE
with IMPERIO GCS
PREP. The preparation module
The baths and chemicals needed for the coating process are often prepared, stored and regenerated centrally. The preparation of baths is carried out using the
IMPERIO GCS PREP recipe control. The information that
consumed fluids need to be topped up is sent automatically via the linked computers.
CONSTANT
PICKLING QUALITY
with IMPERIO GCS
AREG. Das Regeneration module
The cleaning and regeneration of pickling media (e.g.
sulfuric acid retardation system or phosphoric acid regeneration) and other chemicals is performed fully automatically by IMPERIO GCS and is mostly controlled, supervised and documented in discontinuous batch mode
operation.
IMPERIO GCS
EFFICIENCY AND
OPERATING SAFETY OF
YOUR SUPPLY SYSTEMS
systems with IMPERIO GCS
UTILITIES. The supply module
IMPERIO GCS UTILITIES supports you with the media
and other infrastructure with regards to the necessary quantities and constancy. This module is based on
a continuous monitoring of all agents and media. The
temperature of heating and cooling agents, the pressure
of air compressors, fresh air and exhaust fans, as well
as the quantities and temperatures of clean water are
continuously documented. In the case of deviations, the
operator is informed and backup systems are activated.
If production-critical media fail, the production is even
stopped automatically. To enable product calculation,
consumption documentation is prepared, whilst energy
quantities are reported and attributed to the different batches. Energy recovery plants are also integrated in order
to allow for energy-optimized operation management.
TECHNOLOGIES FOR EXCELLENCE
As research and development oriented, international
company group, CPA provides advanced, high-performance technologies for a wide application range in the
fields of wire production, automation, energy and environmental engineering.
According to our core values Competence - Perfection
- Ambition and our corporate principle TECHNOLOGIES
FOR EXCELLENCE we continuously strive for the best.
For the success of our customers.
CPA product lines
• Industrial Furnaces
- AEOX ECC: Recirculation Convection Furnace
- AEOX STS: Microstructure Transformation System
- AEOX EXC: Cross-flow Convection Furnace
• Continuous Plating Plants – Single Cell Control,
Group or Segmented Control
- CELLRAC - GALVOMODUL
• Pickling Plants
- MELPICK
• Electropolishing Plants
- MELPOS
• Fully Automatic Bath Analysis and Control System
- ABACS
• Dryer
- STRYCOC
• Double Capstan - Take-up and Payoff Units
- ROTACC - H
- ROTACC - V
• Tangential Take-up and Payoff Units
- ROXSTA
• Wire-Guiding Equipment - ROLLOC
• Wet Drawing Machines
- LINNOX
• Stranding Machines
- TAUROP
• Process Management System
- Imperio - PMS
• Manufacturing Execution System
- Imperio – MES
• Plating Control System
- Imperio – GCS
• Programmable Logic Controller (PLC)
- Micromatic
- Comatic
• Industry Terminals
- XILOC
• Sensors, Transmitters and Actuators
- PACOS
• Fully Automatic and Manual Flyer Payoffs
- FALSTA
TECHNOLOGIES FOR EXCELLENCE
Changes reserved with regard to
technical development.
CPA Building & Factory Technologies GmbH, Lagergasse 322, 8055 Graz, Austria, phone: +43 (0) 316 46 70 0
e-mail: [email protected], www.cpa.at