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Extrusion
System Control - EPM
Overview
The EPM (Extrusion Process Management) control system is a graphical operator interface that is used to display all relevant processing data.  Input to the control parameters of the process are made via password protected operator input through a touch screen.  RS View SE software provides many features for use in recipe control, real time and historical trending, alarm logging, and report generation.
 
Control System
Allen Bradley’s Logix controller is the actual control device.  Depending upon the functionality required will determine which architecture will be used (CompactLogix, ControlLogix, FlexLogix or SoftLogix).  Each piece of equipment (Extruder, Die, etc.) has its own PLC controller that is responsible for the digital and analog I/O sequencing, screen changer (if required), adapter (if required), integrated temperature control and alarm functions for each machine.  Standard relay programming (which should provide easy maintenance for persons presently using Allen Bradley) is used.  The transfer of selected data from one PLC to another (i.e., pushbuttons, relay status, etc.) allows for much of the control circuit wiring to be eliminated and this data passed through the Ethernet network.  All safety circuits are hardwired from machine element to element to obtain the highest degree of reliability and safety.
 
Benefits
Graphical representation of the line and its functions allow the operator a visual means of determining where the parameters to be changed are located.  When a change-in-process occurs, its location and its effect are readily displayed.  Installation is simplified because of the utilization of the Allen-Bradley Logix architecture with RS View Supervisory Edition.  Maintenance time is reduced because a common database is used between the HMI screens and the project program.  Changes to screens are automatically reflected when changes are made to the program.  Diagnostics are centrally located in a single database to log errors, warnings and informational messages.  Each machine is complete and self contained.  Only the 460V power, network connection, emergency stop, and other safety circuits are required to be hardwired.

The recipe function allows the operator to change temperature profile with the touch of a button.  Recipe Storage has virtually unlimited recipes and contains all the controlled parameter set points that can be viewed before downloading to the machine and temporary or permanent changes made.  Recipes can be created through the recipe screen or by uploading right from the running temperature profile.  A text page is also attached to the recipe so would be available to the operator.

Trending is also available any monitored process value can be selected and displayed on the trend screen.  Each screen will display up to eight trends.  This can be a valuable aid for trouble shooting the process.  Trends can be viewed as either in REAL time or in the historical mode.

Use of the RS View software and Allen Bradley hardware greatly increases the reliability and simplifies the understanding of the equipment functions.  If parts are required, they are readily available from an AB distributor.  The EPM is truly a distributed system as each portion can function entirely on its own.

Use of an operator console that can be strategically located gives the operator a detailed window of the process through which he can control and observe the process with little effort.

A UPS (Uninterrupted Power Supply) to cover the PLC and PC only will be supplied as a standard feature with this system.

This system can also accept data from other PLC (AB) sources via any of the current networks (Ethernet, ControlNet or DeviceNet) and legacy networks (Data Highway Plus or Remote I/O) for material handling, downstream, forming, as supplied by other vendors, etc….  This allows great flexibility and upgrading as the process dictates.

This system can be accessed remotely for diagnostics and service along with remote functioning management.

 
Primary EPM HMI Supervisory Control System consists of:
AB CompactLogix and Allen Bradley’s Logix controller
Industrial Computer 1.6 Ghz min processor speed (minimum)
RS View SE Server Edition
1280x1024, 24-bit color
Windows XP
0-50 degree C (32 - 122°F) operating temperature
Nema 1/4/12 IP65
256 MB (minimum) RAM
20 GB (minimum) Hard disk
17” Touchscreen (21” Optional)
DVD-ROM
 
Redundant Operator Stations for Each Extruder in the System consists:
Industrial Computer 1.6 Ghz min processor speed (minimum)
RS View SE Client Edition
800x600, 256K colors
Windows XP
0-50 degree C operating temperature
Nema 1/4/12 IP65
256 MB (minimum) RAM
20 GB (minimum) Hard disk
12” Touchscreen
DVD-ROM
 
Main EPM HMI on Pedestal mounted off of Rollstand
12” redundant computer in Extruder contactor panel
   
 
 

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