Controls BSH&E SEMINAR

Transcription

1 Controls

2 Content Slide Systems Controls Feeder Controls KCM / KSU / K-Vision / KSC Pneumatic Conveying Controls LSR / MPC /PLC

3 System Controls

4 System Controls Services Sales Support Basic/Detailed Engineering and documentation Manufacturing and installation supervision Start-up and Commissioning Documentation for FAT, SAT, Qualification FAT, SAT including calibration, validation and training

5 Overview Controls Configuration

6 Overview Controls Configuration

7 Overview Controls Configuration

8 PLC Programming PLC (Programmable Logic Controller) Sequence Interlocks Alarm Management Communications HMI (Human Machine Interface)

9 Overview Controls Configuration

10 Supervisory Control Main Screen

11 Feeder Controls

12 SmartConnex Puts the Brain at the Feeder Integrated Package Simplifies Installation and Operation Lowers Cost

13 Comparison Traditional Operator Interface HOST bus SmartConnex K-Vision RS485 Control network HOST bus

14 SmartConnex Traditional SmartConnex

15 SmartConnex Controls K-Vision 10/100 Ethernet connection Protocols: Modbus/TCP, Ethernet/IP (AB) and Profinet-IO Serial connection (RS485-2 or 4 wire selectable or RS232) Protocols: Allen Bradley DF1, Modbus RTU, Modbus Plus, Profibus DP or DeviceNet K-Net RS485 4-wire high speed serial connection with KMB protocol K-Tron Feeders with KCM, KSHM/KSSM, SCM, K10S K-Tron Series 4 MPC for Vacuum Receivers and Loaders

16 SmartConnex Benefits Realize ROI at all times 1. Purchase Fewer components and less wiring mean lower costs 2. Installation Less wiring and off-the-shelf components 3. Communication Host connectiviy at all levels 4. Configuration/ Start-up Simple configuration & less programming needed 5. Operation Improved short-term accuracy 6. Maintenance Remote diagnostics and configuration

17 Controls and Communications K-Tron s SmartConnex TM control environment provides comprehensive control capability with maximum flexibility and connectivity for systems that include feeders, flow meters or PID controlled devices. Single-Line Control K-Vision offers touchscreen operator interface for single process lines consisting of up to 16 feeders or PID devices. Multi-Line Control KSC Smart Commander is a PCbased interface able to control a total of 32 devices in up to 8 process lines. Device-Level Control KCM Control Module combines machine mounted feeder control and motor drive modules into a compact housing, offering maximum flexibility and excellent performance.

18 Device Level Control

19 KCM K-Tron Control Module KCM/SD (Status Display) KCM/KD (Keypad and Display)

20 KCM K-Tron Control Module Compact unit, installed directly at the feeder Software for screw feeders, BSP feeders, belt feeders, Smart Flow Meters and PID available Host communications via Smart K-Link Integrated controls for vacuum conveyor or vertical agitator Models with and without Display ATEX 3D

21 KCM K-Tron Control Module Software matched to the controlled device Continuous or batch operation Local or remote mounting Network interface Patented screw speed modulation algorithm Integrated refill control Extensive host communication capabilities

22 KCM User Interface 3.5 inch color LCD Real Time Clock 5 built-in languages One custom language file can be uploaded e.g. Chinese, Japanese, Korean, Russian

23 KCM Drive Boards KCM/../DC 450 Watt DC Motor Drive Board 1600 Watt DC Motor Drive Board Vibratory Drive Board Stepper Motor Drive Board (43,194W) KCM/../AC AC Motor Interface Board used with external VSD (Variable Speed Drive) eg. AC Drive, Servo Drive etc.

24 KCM Connectivity Communication Protocols Modbus RTU (KCM Slave) Allen Bradley DF1 (KCM Slave) Modbus Plus Modbus/TCP Ethernet/IP Device Net Profibus DP ProfiNet

25 KCM Basic Control LIW controller adjusts feeder speed to produce a rate of weight loss equal to the desired feed rate setpoint

26 KCM Control Features: Speed Modulation In general screw feeders produce an irregular material flow within one screw revolution, resulting in a pulsation of the massflow. Massflow (kg/h) Volumetric with constant screw speed Massflow Drive Command Time (s) Drive Command (%)

27 KCM Control Features: Speed Modulation Electronic speed modulation minimizes the pulsation of the material flow: Short-term accuracy improved by a factor of 2 2-Sigma accuracy at a 10 second sampling time improved tremendously Ideal for low feed rates (speed < 1 screw rotation per second) Massflow (kg/h) Volumetric with constant screw speed Massflow Drive Command Drive Command (%) Massflow (kg/h) Gravimetric modulated with volumetric phase Massflow Drive Command volumetric phase Drive Command (%) Time (s) Time (s) 10

28 KCM Control Features: ActiFlow Hopper Feeder Weighing System ActiFlow Device Serial Channel Coil Power / Position Feedback ActiFlow Control Unit Motor Power / Speed Pickup KCM KCM

29 KCM Control Features: Refill Algorithm The weighing sensor technology (SFT) and KCM refill algorithm allows K-Tron to supply smaller feeder hoppers for more frequent refills 12 or more refills an hour

30 KCM Control Features: Conveying Support LSR Integration LSR = controller for Loader or Single Receiver LSR communicates with KCM via serial link or hardwired I/O KCM fully supports the LSR functions accessible on the KCM display

31 Feeders with KCM

32 KSU-II K-Tron Single Unit K-Tron Feeders with KCM and KSU II Operator Interface for a single feeder at the same time (for maintenace purposes) Can access multiple feeders on single network Vacuum-fluorescent display IP65 housing ATEX 3D compliant Screen setup as per connected KCM

33 Single Line Control

34 K-Vision Basics 10.4 color touchscreen Integrated solution Supports all K-Tron controls Supports pneumatic conveying controls 16 Feeders in one process line Easy to use

35 K-Vision Connectivity K-Vision 10/100 Ethernet connection Protocols: Modbus/TCP, Ethernet/IP (AB) and Profinet-IO Serial connection (RS485-2 or 4 wire selectable or RS232) Protocols: Allen Bradley DF1, Modbus RTU, Modbus Plus, Profibus DP or DeviceNet I/O Board One analog in, One analog out Two relay outputs, two digital inputs K-Net RS485 4-wire high speed serial connection with KMB protocol K-Tron Feeders with KCM, KSHM/KSSM, SCM, K10S K-Tron Series 4 MPC for Vacuum Receivers and Loaders

36 K-Vision Quad screen mode view of multiple pages on one feeder or a single page on multiple feeders Multiple language support, including Chinese and Japanese Event logging and flexible, easy-to-use trend graphs Software updates via serial download or flash memory exchange

37 Quad Screen Four independent panes of information

38 Language Support

39 Event logging Trend graph is color coded Blue = Setpoint Green = Massflow Black = Weight

40 Multi Line Control

41 K-Tron Smart Commander Multi-line Control, SCADA package KSC software controls up to 32 devices in up to 8 independent continuous or batch process lines animated graphics display of feeder operation, vacuum sequencing systems, refill, etc. Virtually unlimited storage or recipe and material data Real-time historical trending data and alarm management

42 Pneumatic Conveying Controls

43 Pneumatic Conveying Controls LSR Loader Single Receiver Controller MPC Series 4 (Microprocessor Controller) Up to 24 receivers on 1 vacuum pump PLC Series 4 Controller (Allen Bradley or Siemens) Up to 32 receivers on 4 vacuum pumps

44 Vacuum Receiver Controllers LSR Controller Operates with either one self contained loader or single central receiver with separate blower.

45 Vacuum Receiver Controllers ATEX Version MPC Controller Controls up to 24 vacuum receivers on one blower with one back-up blower. Built-in K-Modbus communication

46 Vacuum Receiver Controllers Series 4 PLC Standard Package handling up to 32 receivers and 4 blowers. Allen-Bradley or Siemens PLC with Touch Screen HMI Pre-programmed for full system of receivers that can be customized Support for remote access

47 MPC with LIW Feeders Series 4 with LIW Feeders Receiver Panel MPC K-Bus RS485 4-wire Signal Refill K-Vision