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Weighing and dosing
Tracing back of process data
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30 years of experience in the field of automation of weighing, mixing and dosing processes
With an experience of more than 30 years in the weighing and dosing sector of automation, KELLER HCW supplies turn-key plants including mechanical components and swich rooms as well as installation and commissioning. The entire automation – including weighing and dosing modules based on software for liquids and solids – can be realized with a Siemens PLC-based system.
• Concept solutions on the basis of the standard Siemens T.I.A.
• Complete concept based on modern control units
• No interface problems or complex data exchange
• Protection of investment by the use of standard components
• Dynamic document and program structure
• All employees can access data due to the client/server structure of the software
The automation system is completed by recipe administration and recording of batches.
• Dosing process according to recipe
• Intuitive user interface
• User-friendly method to draw up the recipe and protocol the batches
• Object-oriented modules
 Contact:
Uwe Hartmann
Division Manager Measuring/Controlling
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Telephone: +49 5451 85-485
e-mail: uwe.hartmann (at) keller-hcw.de
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Software modules
The demand for complete system solutions within the weighing and dosing sector of automation has become more and more frequent. Individual weighing and dosing units cannot fulfil the sometimes complex requirements, for instance in regard to material supply and transport. KELLER HCW offers an innovative system solution. Entire automation – including weighing and dosing modules based on software for liquids and solids – can be realized with a Siemens PLC-based system.
Characteristic features:
• Complete concept based on modern control units
• No interface problems or complex data exchange
• Flexible document and program structure which can be easily upgraded
• Protection of investment by the use of standard components
• Dynamic document and program structure
• All employees can access data due to the client/server structure of the software
Depending on the capacity of the plant, the entire system can be operated alternatively by a text-oriented operating and monitoring unit and/or via visualization. As an option the entire automation system can be supplemented with a program for monitoring recipes and recording batches.
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Recipe administration and recording of batches
Characteristic features:
• Dosing process according to recipe
• Intuitive user interface
• User-friendly method to draw up the recipe and protocol the batches
• Object-oriented modules
This solution can be employed in all industrial sectors, even with explosive materials, and has been successfully used in the food industry, at asphalt mixing plants and paint and dye mixing plants, etc.
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Complete solutions from one source
KELLER HCW is able to offer complete system solutions including control hardware, visualization, recipe monitoring and installation due to many years of experience in the field of weighing and dosing automation. As required KELLER HCW can supply turn-key solutions including the individual mechanical components.
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Teleservice
The worldwide Teleservice belongs to the standard components of the KELLER HCW systems.
KELLER HCW projects modular and non-standard Teleservice solutions optimal adaptable to customer system.
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Mixing facilities
Mixing facility with Simatic S7, WinCC and recipe program
The assigned task:
Loryma, a starch processing company in the Hessian town of Zwingenberg, wished to have its new mixing facility automated. The facility consists of two mixing lines which are both fed by outdoor silos (large components), big-bag stations (medium-sized components) and small bins (small components). For each mixing line a 1200 kg scale is used for intermediate storage. The small components are metered by a 25 kg batching scale hopper, fed to a pressure vessel and in turn transferred to a 1200 kg scale. The material is conveyed pneumatically. As an option, large and medium-sized components can be conveyed to an inline pressure sifter. Recipe-controlled metering is to be monitored and operated by means of the visualisation. Both mixing lines are to run parallel and to be able to simultaneously process different recipes. To avoid demixing, the material is to be discharged in sub-batch quantities before proceeding to the packaging unit.
Solution:
The KELLER HCW company developed a new control system based upon the programmable logic controller (PLC) of the Siemens Simatic S7 Series. A CPU of the S7-400 family and the Siemens WinCC visualisation system are the core of this new control system. The system is supplemented by a PC installed with the recipe program by KELLER, which, in addition to the common preparation and administration of the recipe, also encompasses job order management, batch record-keeping and an analysis of material consumption. The plant can be operated either by means of the visualisation or with the OP17 operator panel situated at each mixer. Furthermore there are OP07 operator panels at each of the outdoor silos and at the midsized and small components. An ethernet processor with TCP/IP protocol is employed to communicate with the visualisation and the recipe computer. The operator panels are connected to the central controls by means of Profibus DP. The task of connecting the decentralised inputs and outputs to the tanker unloading station was accomplished with ET200S modules.
The KELLER Weight Amplifier IM62 AF1 is used to record the weight registered by the scales. The IM62 AF1 has a standardised linear analogue output which is directly connected to the PLC. Software modules of the PLC are used to implement such typical functions such as metering, taring, automatic setting to zero-point, motion detection and scaling down adjustment. Since these modules take over the job of external weight indicators, common interface problems are avoided. Another distinctive characteristic is the interplay between the individual control system components. An prime example: once bins and receptacles have been defined in the recipe program according to number and ingredient name, this information is automatically communicated to the visualisation and operator panels. When new materials are introduced or the contents of a bin changes, neither the PLC program nor the visualisation need to be modified. A single data entry to the bin chart of the recipe program will suffice.
Commissioning took place in the remarkably short time of one and a half weeks.
This was made possible by the modular software programming developed by KELLER HCW. Among other things, the PLC function modules contain a built-in simulation, which allows the client to extensively test the control program in combination with the visualisation and recipe program. Furthermore, KELLER HCW was able to demonstrate to Loryma the complete functioning of the plant prior to initial operation. Modification requests and errors were recognised and rectified in advance.
The starch plant is provided with a teleservice. If a failure or a malfunction should ever occur, KELLER HCW personnel can be of immediate assistance in analysing and solving the problem.
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Platform scale loading
Assignment:
A large flour milling plant required a modification of its systems control for five loading lanes with vehicle platform scales and for the entrance and exit scales.
Loading and conveyance were controlled by a Siemens S5 PLC. A self-contained weighing terminal, which was serially connected to a scale PC and a PLC, served as a scale.
System modification had become necessary due to hardware failure such as damaged wiring between the scale and the scale PC, interface problems, a need to rationalise and a faulty scale PC. Additionally the mill wished to have its loading system interconnected to its commercial / administrative software.
Solution:
The S5 controls – in addition to loading – fulfilled other pertinent technical functions. For this reason as well as due to the expense, a complete replacement of these components was not considered a viable option and not even necessary for that matter. The problematic scales were replaced with four Simatic S7 controls with Siwarex M with an OMNI Scale data storage (alibi printer). Three of the S7 controls were employed to control two scales apiece. Configurating the system in this manner is qualifiable for gauging certification. The PLC S7 controls serve to control the loading procedure and coordinate the Siwarex and the existing S5 controls.
Although self-contained loading administration is possible with the new system, the weighing software is coupled to the commercial/administrative software. This enables an order which has been processed by the commercial / administrative software to be taken on by the loading / consignment software so that loading can take place.There is no longer the need for double entry of orders in the administrative software and in the loading-PC, thus resulting in a 50% cost reduction and in the prevention of possible input errors which might be made when entering data twice. The dispatching clerk enters the order data in the administrative software.
After loading has taken place the system reports back to the commercial administration with the loading / consignment data. The administration software generates the invoice and delivery note which represents an additional costcutting measure since the scale values do not need to be input manually. A second PC with weighing software is connected at both the entrance and exit scales where the grain is received and the complete material flow is processed. This PC serves the scales and the administration of the receipt and issue of the goods, including information about material in process. This PC also contains a client and article data base so that a goods issue slip indicating weight and time can be generated and printed.
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