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Ceramics
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Everything runs smoothly
with KELLER HCW automation and control systems
The Company Division Automation and System Engineering of KELLER HCW GmbH is giving its full support to Totally Integrated Automation (T.I.A.). The effective solution to a great many automation demands can only be achieved with a completely integrated, universal system, from the Field Service to the Management level. Decisive factors for the functional viability of the entire system are comprehensive know-how and design with assured future using components in optimum co-ordination with each other. A competent partner is needed for this, who will take over the engineering and project management, the completion of the project, the site erection and the service.
 Contact:
Dipl.-Ing. Josef Schröter
Head of Electrical Engineering, Automation and Process Technology
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Telephone: +49 5451 85-558
e-mail: josef.schroeter (at) keller-hcw.de
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Control SIMATIC S7
Control of all plant and machine components at the plant installations is performed by Program Control System SPS-Simatic S7 (400/300).
Coordinated components and standard interfaces ensure smooth running. As well as the traditional control and technological functions, data processing operations are increasingly required, such as process visualization, data collection and interpretation.
The decentralized design of the KELLER HCW automation plants with the ET200 peripheral units has been prepared for the future-orientated PC-based Control Solutions.
PC-based Control as a combination of control and data processing
on one PC opens up new horizons for automation technology.
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Industrial PC
Adapted to client-specific application, the industrial PCs are assembled in the successful standard operating system Windows NT to form a complete system ready for operation.
The simple and uniform projection with WinCC Simatic industrial software, WinCC visualization, Activex, Visual Basic and standard data banks helps to save expenditure on engineering and service. Multitasking and real time behaviour guarantee the systems are working to optimum capacity with high safety.
The well-known Windows surfaces, menus and selection boxes in widespread use offer maximum flexibility both for configuration and parameterization, and also for process image generation and modification.
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Operation desks
A new family of control panels sets new standards in regard to the control and operation of the machines.
Industrial PC or Operator Panel (19", Front IP 65) with key pad or touchscreen and reliable command devices installed in the case system Command-Panel VIP 6000 offer optimum ergonomic conditions for the operating personnel.
The transfer of the connection cabling to the foot of the operator panel facilitates the erection, commissioning and service. Network interfaces and power supply are constructed outside and are accessible for external devices, such as e.g. programming devices.
Sturdy construction of the components renders the system capable of application, even under severe operating and difficult environmental conditions.
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Teleservice
The worldwide Teleservice forms part of the standard modules of KELLER HCW plants.
The Company Division Automation and System Engineering of KELLER HCW projects teleservice solutions modular and individually adapted to any client’s plant.
Complex transfer of data with Router and Secure Access Firewall, ISDN Interface, LAN connections, integrated digital modems, HUBs and videoconference line are integrated in the plant network.
In case of defect, the cause of machine or operation faults can be located in a very short time by a specific diagnosis. With today’s technical facilities the availability of automation and process control systems can be considerably improved by means of remote support maintenance.
Direct access to expert knowledge is the ideal conditionfor avoiding protracted downtimes of the plant. If necessary, the service specialist can intervene directly in the plant control system. The Teleservice permits remote visualization and control of the plant, programming of the process control computers and of the Programmable Logic Control Systems (PLC), specific analyses of the operating and fault messages and also file transfer of software updates and documentation.
Since the introduction of the teleservice system, most of our customers have decided in favour of this future-oriented additional investment.
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Videoconference system
The video conference installation opens up a new dimension in fault analysis and fault recovery. Protracted and complicated explanation of problems by telephone are now a thing of the past. Downtimes of production plants can be reduced considerably by means of an appropriate multimedia video conference installation.
Specialists and decision-makers can be called in worldwide without travelling time. Customers, suppliers or members of staff can be given personal training or service even over large distances. Short ways of coming to a decision prevent unnecessary waste of time and ensure important advantages in competition.
The video conference system was kept deliberately open in concept and is therefore compatible with video conference systems of other manufacturers. It is based on standard components on the market, which can be exchanged or retrofitted at any time. High quality of the technical components ensures high production efficiency.
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Visualisation
The machine visualization forms a connecting link between the Programmable Logic Control System (PLC) and the operating personnel of a plant. Complex technical processes are presented graphically and comprehensibly. Use of the machine visualization gives every operator an opportunity to intervene in the production-relevant areas of the entire plant. The machine visualization is located in immediate proximity to the plant components to be operated. To provide centralized observation of the flow processes of the entire production, a supplementary machine visualization can be installed in the switch control room.
The machine visualization assumes various functions for the area of automation and materials handling technology in the section adjoining the machines:
• Visualization of the operating states
• Control and parameterization of the plant
• Manual functions for plant operation
• Indication and output of fault messages and warnings
• Analysis of fault messages over relatively long periods
• Production data collection and representation
An integral KELLER analyser for fault messages facilitates the search by the plant operator for a cause of failure. Apart from the plaintext of a fault, the module in the plant-specific circuit diagrams and also programming module in the corresponding Programmable Logic Control System (PLC) are displayed. The downtimes of a machine can thus be minimized.
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Tunnel kiln and dryer
KELLER HCW GmbH process computers are characterized by ease of operation by Window-Standard, ease of curve generation for firing or drying with graphic support and also easy parameterization of the plant. No knowledge of computers or of programming is necessary for operating the process computers.
A high level of operational reliability is achieved by decentralized intelligence. In case of failure of one component, this does not necessarily mean that the entire process comes to a standstill. Optimization of the kiln or dryer operating characteristics is obtained by continuous monitoring of the firing or drying processes and automatic adaptation of the control of critical operating states.
A firing or drying curve with optimum adaptation to the operating state at any time in conjunction with control loops guided by setpoint values results in a reduction of energy consumption and an increase in productivity. Data exchange with other computer systems via integrated communication interfaces (Industrial Fast Ethernet TCP/IP) forms part of the standard equipment of the process computers.
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Chamber dryer
The idea of having an integrated automation design is logically continued in the recently developed surface of the chamber dryer computer (operating system Windows NT, Scada- System Simatic WinCC).
In this new development also special attention has been paid to ease of operation without knowledge of computers or programming. Measured data, setpoints, messages and balance data are stored in a data bank and are available there for interpretation.
Flexible control programs afford an opportunity for reacting to the requirements in the chamber dryer and of optimizing the energy consumption. Consistent database organization in regard to variable connection and integrated communication (Industrial Fast Ethernet (TCP/IP) characterizes the system.
Based on decades of experience of KELLER HCW in dryer construction, a system has been evolved which, due to its modular structure, can be adapted to all individual requirements.
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MIKOS
The System K-matic MIKOS is applied to the collection and analysis of production data. It forms the link between the Production Management and the Company Management or the commercial planning levels. The basis for all functions of the system is the counting of production volumes at the exit from selected machines or groups of machines and the recording of production times. All production data are automatically stored in the data bank of the server.
All production data are automatically stored in the data bank of the server. The individual data and statistics permit a wide range of operating tests. Thus, inter al. the degree of utilization of plant capacity can be calculated. Productivity analyses can be carried out with no difficulty because of the information available.
With the use of MS-Office Production the design possibilities opened up by the evaluation of the production data are virtually unlimited. The combination of WinCC WebNavigator Server and Client allows plant monitoring and operation via Inter- or Intranet. On the part of the clients merely a Web-Browser and a minimal installation are needed. The production data are becoming more transparent.
They can, according to requirements, be related to each other, presented and issued. MIKOS is extremely flexible and can be employed for all fields of industry where production processes have to be monitored, documented and evaluated round the clock. When developing k-matic MIKOS, we always had the end-user of the system in mind.
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Kiln car tracing
In the plant overview a graphic presentation is given of the arrangement of the transfer cars, tracks and tunnel kiln cars (TKCs). The tunnel kiln cars (TKCs) are indicated with their corresponding TKC number, the state of loading and their present position within the plant. Detailed information, such as the format number, model description, colour designation, weight, unit number, status of the ware (dry, fired, wet) and comment can be recalled by mouse click on the required TKC.
If the properties are to be modified, the user can then edit the TC data. The editing of the values is protected by a Password. By means of the integrated communication to the TKCs-SPS (Simatic S7- 400, Industrial Ethernet TCP/IP), erroneous addressing of the variables is excluded during parameterization. Areas of the plant which are difficult of access can be monitored permanently with camera control on the kiln car tracing OWV computer.
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