IMPERIO GCS IMPERIO GCS
Transcripción
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