Parijat Aluminum Extrusion SCADA

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Aluminum Extrusion System Solution

The goal for extrusion operations is to produce the highest quality product at the lowest possible cost. Securing this efficiently requires a change in paradigm from operators pushing buttons and manually collecting data – to presses running in complete automatic, performance and production data being collected and transferred to the business, ERP system, while the equipment operators function as technicians concentrating on improving quality and productivity. The business, ERP system may be an existing 3rd party system like SAP, Oracle Financials, M2M, Infor, MS Dynamics, epics, etc. or it may be the integrated business systems option of the Parijat system.

aluminium extrusion typical solution

Fig: Aluminium extrusion – Typical solution

A Typical aluminum extrusion system solution consists of various software silos or islands from different vendors’ software products with multiple copies of data, also requiring a lot of manual data entry activities that are prone to human errors.

PCI solution combines all of these activities into a single software application with a single copy of data. This eliminates any data integrity complications & vulnerability to human data entry errors.

aluminium extrusion pci solution

Fig: Parijat’s Aluminium extrusion – PCI solution

Automation:

To get to this level, the press system – beginning with the billet/log heating and cutting system; billet loading system; press cycle, auto Die change; lead out table / hot saw/puller; profile handling transfer / stretching system; Cold/finish saw infeed, cutting, queuing, and offloading systems must be balanced and PLC’s capable of communicating between themselves, running in automatic closed-loop control mode and the PLC’s making process adjustments based on equipment settings, positions, and computer algorithms all with minimal operator intervention. Examples of this type of automation are:

1. Automatic billet call settings based on press ram speed, billet length, and dead cycle time
2. Die Copy actual weight per unit length calculation based on puller positioning and billet size.
3. Automatic adjustment of billet length to maximize recovery, and minimize press time
4. Billet length calculations based on last recorded weight per unit length of die copy.
5. Smoother & faster press cycle & smaller dead cycle time – even less than the press vendor spec.
6. Safety interlocks –

  • Puller safety light curtains
  • Hot saw protection
  • Press safety alarms/stops – ram obstruction, billet misalignment, butt fall detection, short tool stack

7. Auto-generated shift reports & statistics – quantity of billets run, gross weight extruded, number of die changes, contact time
8. Automatic burp pressure settings to minimize blisters, burp cycle
9. Hot saw positioning in conjunction with billet length calculation to maximize recovery
10. Automatic position/release of extrudate via recipe versus operator, or time-controlled
11. Ram speed adjustments based on exit temperature (InfraRed Pyrometer) and billet temperature
12. Finish saw automation, unattended operation after the stretcher trim is cut off so the saw operator can assist in racking metal

Tracking & Traceability:

Parijat system uses advanced video analytics, Big data & IIoT (Industrial Internet of Things) to track & trace the materials used from the entry of logs/billets to the finished products at plant exits.

Communications – Data Collection:

Up till now data collection and analysis was quite arduous – many times data is not thoroughly collected or analyzed to determine what is preventing the current system from running optimally – getting to the root cause is the key. Even the oldest presses have the potential to run in fully automatic or as a bare minimum semi-automatic. Parijat SCADA data collection system will provide real-time press performance and identify roadblocks to excellence. Parijat integrated single system will provide the cost savings models by modifying or correcting the issues which are keeping the press from being very profitable.

Once the press system is functioning at full potential, optimum recipes (press parameters) can be generated beginning with the highest volume shapes. These recipes get automatically pushed directly into the PLCs, once again reducing operator keystrokes and potential for human error. Infinite quantity & extensive recipe management system helps with the process optimization also. Parijat PLC programs & the PC software harness the full power of both sides coupled with the domain knowledge of Aluminum extrusion. This is done by focusing on total end to end Systems Integration:

  1. Develop drivers and software to cohesively integrate existing press PLCs with existing business systems (ERP, MRP) or also perform those functions if an ERP system does not pre-exist as an integrated system.
  2. An extensive die management system to provide the tools to effectively analyze the performance of the presses down to the profile level, including automatic Die change over, if physical mechanisms exist.
  3. Presales quoting system – provides a quoting model which provides the production estimates and the optimum number of holes in a die. In a multi-press operation, this can be provided by multiple cost/profitability estimates based on different presses.
  4. Scheduling – provide easily manipulated Press Schedule – using existing ERP, MRP system. Including optimizing billet length, hot saw position, multi drags, multi push based on actual weight per unit length of the profile.
  5. Collect – Labor, Burden, number of billets, length of billets, alloy, alloy lot number, actual weight per unit length of extrusion, and run success based on PLC data communications without the need for the operator to input this data manually.
  6. Collection of “real downtime” or lost time – The following diagram shows the time distribution of a typical extrusion 21-hour workday.
  7. Use of smart industrial buses like Ethernet, ControlNet, Devicenet, Profinet, etc. to significantly reduce wiring.

time distribution

Fig: Both Shifts Time Distribution Hour

Contact time is the time the press is under pressure (the paid-for-time). Dead Cycle Time is based on the average actual press dead cycle times the number of billets runs. Cleanup, log oven issues, meetings, and die setup are typical maintenance and production downtimes. After all, are collected and summarized over 10% of the available production time is unaccounted for. Once the contact time is analyzed versus the ideal recipe, the norm is that there are approximately 10% inefficiencies in the extrusion time. Parijat goal is to help recover this time, reduce operational costs and open additional capacity by helping resolve these issues.

Parijat can help optimize the control systems and processes.

There are a number of other services Parijat offers, beyond troubleshooting, optimization, and integration.

Training – Parijat team is fully capable of training the client’s maintenance personnel on multiple PLC platforms – Rockwell, Siemens, GE, Schnieder, Mitsubishi, Honeywell, to name a few.

PLC Upgrades – if the current press control system is running outdated PLCs, Parijat can help upgrade it to the latest software and hardware available & harness its power to the fullest.

EMMT – Extrusion Maintenance Management Tool – this is an instant interactive, intuitive. Visual fault diagnosis & troubleshooting tool for the maintenance team to troubleshoot equipment, without the PLC technician having to pull out the laptop and analyze the ladder logic. Parijat provides plant team members a virtual road map for troubleshooting which will significantly reduce system downtime by minimizing the troubleshooting of the equipment – EMMT points in the right direction.

Various OEM equipment that may be supported:

  • Presses: UBE, SMS Meers, Mei-Ruey, Tecalex, Presezzi, Gia Clesim, Siddharth heavy ind, Guangzhou DT, Danieli, Kautec,
  • Shears: Belco, Granco Clark, Omav, Tecalex, Cometal, Kautec, Presezzi, SMS Meers, GIA Cleceim, Turla
  • Furnaces: Belco, Granco Clark, Omav, Tecalex, Furnace Engineering Pty Ltd, Cometal, Kautec, Presezzi, GIA Cleciem, Turla
  • Pullers: Granco Clark, REISCH Maschinenbau GmbH, Cometal, OMAV, Kautec, Presezzi, Belco, Turla
  • Straighteners: SMS Meers, Butech Bliss, Granco Clark,
  • Other Ancillaries: Tecalex, Omav

To begin the process, Parijat requires as much detailed information on press configurations as follows:

Press Name or Designation
PLC make/model (if any)
HMI make/model (if any)
ERP Software (if any)
MES Software (if any)
Other peripheral software in use (if any)
LOG OVEN
Log diameter
Maximum log length
Minimum log length
Maximum billet length (in the press)
Production capacity (kg/hour)
Type of fuel
Log Shearing force
Tapering zone?
Nº of thermocouples (zones)
Furnace length
Heat recuperating unit length
Maximum Billet temperature
Temp. uniformity with furnace
BILLET HANDLING SYSTEM
Log Shear, log Saw or Cut Billet
Transfer to press loader method
Cutting Tolerance
Cycle time from time oven furnace opens until billet ready to be loaded in press
PRESS
Tonnage
Manufacturer
Date of Manufacture
Last Upgrade
PLC and Model
Number of High Pressure pumps and Manufacturer
Working hydraulic press
Maximum Billet Diameter (COLD)
Maximum billet length to be extruded
Maximum extrusion speed
Dead cycle time (with Burb cycle)
Dead cycle time (without Burb cycle)
Container Heating – radial, longitudinal, multizone
Front Loading, rear loading, moving stem?
TOOLING SIZE
Diameter
Thickness
Die Slide, Die Shuffle, gatelock
BUTT SHEAR
Blade type – manufacturer
Knocker
HOT SAW
Manufacturer / Date
Diameter of Saw Blade
Minimum Position from Platten
Maximum Position from Platten
HANDLING SYSTEM
Manufacturer / Date
Maximum profile height
Maximum profile width
Width of run-out roller conveyor
Length of lead out table
Length of run-out roller conveyor
Maximum profile length
Minimum profile length (for stretcher)
Pulling force adjustable
Puller rails
Inside width of puller jaws
Maximum return speed
Maximum removing speed
Maximum extrusion speed
Cooling table length
Dimensions of belt T1
Dimensions of beltT2
Dimensions of belt S1
Dimensions of belt S2
Dimensions of belt S3
Stretching force

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