New K-matic K and K-matic TD process computer system for tunnel kiln and tunnel dryer control systems made by KELLER HCW
[August 2006] The new K-matic K and K-matic TD process computer systems for tunnel kilns and tunnel dryers are based on the long experience KELLER HCW has had with the development and practical use of process computer systems in the ceramic industry. The latest hardware and software is used for the control part (PLC) of the new system as well as for the process computer part. However, the system remains compatible with existing and older control systems which are at least equipped with Simatic S5.
System structure
The control and regulation system consists of the switchboard with PLC and the operating unit, as well as the process computer. By means of the PLC, the digital and analogue signals are processed and controls implemented by software controllers. Manual operation of the plant is achieved by means of the operating unit integrated into the switchboard. The control system is connected to the process computer via Ethernet TCP/IP. The computer is equipped with a 19" TFT display, accident prevention supervision devices, DVD burner for data storage and WINDOWS XP PROFESSIONAL operating system. By process connection via Ethernet the computer is able to collect data from various computers or control systems inside the network. A network-compatible colour printer will serve for data logging. A designer desk is provided for the process computer.
Data logging
All process relevant data is collected by means of the digital and analogue components integrated into the PLC control system. By the Ethernet interface the process computer is able to read, display and store data from different control systems. The data collected by the computer may be of any type. In addition to external, internal data like balance values, calculated data and all user entries with data and time are collected.
By means of the transport control system integrated into the PLC, complete car tracking is established and those processes historically archived.
Process management
The highlights of process management are:
• Automatic presetting of set values, limited values, controller parameters, pulse control parameters and type of firing (e.g. reduction, salt) by integrated car tracking.
• Automatic adaptation of the firing curve with the movement of the product through the kiln.
• Any number of firing curves to which different set value programmes, limit value programmes etc. are available for different production capacities.
• Automatic adaptation of firing curve to intermediate output stages.
• Supervision of heating-up and cooling velocities with automatic alteration of firing curve and pushing time.
• Set value guidance which can be connected separately for each control circuit. (Positive set value guidance, negative set value guidance, gradient and calculated set value).
• Track positions for set value calculation of separate control circuits are freely programmable and are shown as each partial pushing process.
• Programmable modification of kiln output for bridging weekends and holidays with as many salient points as required.
• Freely configurable reduction programmes with 16 time segments per partial push, switching on and switching off of units and reduction set values for each time segment.
• Integrated tunnel kiln car and tunnel dryer car tracking with historical presentation, car protocols, pre-programming of processes.
Filing and backup
All data like measured values, set values, failures, system reports, balance data, tunnel kiln car protocols, interventions by users etc, which are collected by the control system or the computer, can be filed. All data is stored with date/time in a MICROSOFT SQL-SERVER databank. The values are available at any time (fixed disk capacity).
Daily online backup is carried out automatically while the programme is running. The backups can be burnt on DVD and serve for data storage as well as for data filing. For analysis purpose old data sets can be copied from DVD back to the running system. Thus, all data is available at any time.
New functions
In addition to the known and proven K-matic functions the new system is extended by some highlights:
• Completely revised operating surface. Simplified entry of set values and parameters according to latest WINDOWS standards.
• As many visualisation patterns as required can be stored. The patterns can be modified or newly prepared by the user during running time using the integrated graphic designer.
• By means of "history players" processes from the past can be played by time-lapse. Therefore, for example the tunnel kiln car transport can be followed.
• All relevant set values, measured values, balance data etc. can be directly exported into files (e.g. MS-EXEL), so that they can be worked on using other programmes.
• By communication via Ethernet, data can be collected and processed by all network participants.
• In the configuration level each separate variable can be addressed, the data type can be determined, the collection cycle is adjustable and filing is configurable.
• Manual operation can be achieved by separate controllers and drives via the operating unit on the switchboard as well as via the process computer.
• The operating surfaces can be designed with several languages.
• A MICROSOFT SQL-SERVER databank serves as data basis which is also suitable for data exchange with external systems.
• The online data filing is only limited by the capacity of the fixed disk. By means of the installed DVD burner monthly files can be stored externally as endless files.
• On the computer each failure report can be provided with a delay time. Furthermore, it is possible to send failures as SMS or telephone message.
• All inputs are recorded with date and time as well as modified values.
• Calculation of set values and parameters has been improved and can now be exactly adapted to each partial pushing process in case of changes of size or output.
Summary
All functions of the known K-matic system from the past have been included in the new system. Access to the new systems is facilitated by the same menu structures. Due to the extended configuration possibilities the process computer can also be used for older computer systems.
The process computer system ensures a very high operational reliability by outsourcing all operation-relevant control and regulation tasks into the PLC.
Due to the extensive automation functions and the extended filing of all relevant process data a reproducible production is guaranteed.
By continuous supervision of the firing and drying process and automatic adaptation of the control system to critical operating conditions (heating-up, cooling) an optimised kiln and dryer operation is achieved.
A firing curve/drying curve adapted to the operating status at any time in connection with set value guided control circuits results in the reduction of energy consumption and in an increase in productivity.
Further information can be found under the following link:
Brochure 09/2006 »
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