Nowoczesny automat galwanizerski

Nowoczesne linie galwaniczne pozwalają osiągnąć wysoką jakość produktów w połączeniu z wydajnością i oszczędnością dodatków chemicznych oraz energii. Jednym z najważniejszych elementów automatu galwanizerskiego jest jego system sterowania czuwający nad powtarzalnością procesu.

 

ekran glowny

 

Pełna modułowość

Pragniemy zaproponować Państwu niezawodne narzędzie do precyzyjnej kontroli przebiegu procesu na liniach galwanicznych. Jego modułowa konstrukcja pozwala na elastyczne dostosowanie do każdego rodzaju produkcji (cynkowanie, chromowanie, miedziowanie, niklowanie i inne). Nasz produkt stanowi idealne rozwiązanie zarówno do obsługi zaawansowanych procesów jak i do sterowania małych linii galwanicznych. Doskonale nadaje się do wykonania modernizacji galwanizerni w celu podniesienia wydajności i powtarzalności produkcji.

Reliable hardware solutions

iGAL control system operates on the basis of B&R hardware solutions – leading provider of integrated solutions for various industrial branches. A wide knowledge of all areas of machines automation and usage of different processes operation techniques are the foundation which makes us strong and credible business partner. We offer our clients state-of-the-art automation solutions coming from one source: no unnecessary interfaces, the maximum flexibility and exceptional profitability.

2 sprzet 05

Hardware configuration

  • Control unit with the computing power is equipped with universal interfaces and fieldbus which enable easy integration with devices.
  • Reduction of wiring by application of distributed control system.
  • The application of industrial communication networks ensures better diagnostics of drives, I/O modules, rectifiers and other peripherals.
  • Visualization of process, projected on high resolution touchscreen displays or computers.
  • Remote access / diagnostics through the Internet.
  • Possibility of communication and data exchange with other installations (e.g. wastewater treatment plant).
  • Control system is designed according to norms and regulations on the safety of machinery.
  • Modern absolute positioning system.
  • Modularity and flexibility of digital, analog I/O modules and communication interfaces. Easy adaptation of applications to various configurations. It is very useful in modernizing electroplating lines.
  • Reliability and high product quality thanks to the application of components of the best manufacturers.

 

konfiguracja sprzetowa 00

Produkcja pod kontrolą

  • Precyzyjna kontrola przebiegu procesu produkcyjnego
  • Wizualizacja dająca pełen obraz produkcji
  • Intuicyjna obsługa
  • Parametryzacja pracy urządzeń wchodzących w skład linii
  • Edycja wartości parametrów procesowych oraz receptur
  • Zaawansowane ustawienia w trybie serwisowym
  • Logowanie użytkowników
  • Pełna diagnostyka urządzeń
  • System alarmowania, rejestracja historii alarmów
  • Rozbudowane raportowanie przebiegu produkcji i wartości procesowych
  • Archiwizacja danych, zapis na dysku, wysyłanie raportów na e-mail
  • Zdalny dostęp poprzez Internet (obsługa, diagnostyka, serwis)
  • Obsługa za pomocą urządzeń mobilnych (tablet, smartfon)

 

Functionality

  • A new approach to transporters control. The possibility of simultaneous product processing of various technological programmes (process course) and recipes (times of processes, currents, additional options). In contrast to the traditional way of controlling, there is full option of changing the transporters working mode and restarting the automatic operation at any time.
  • Optimized trajectory of manipulator movements, which enables the maximum use of the tanks. The transporters carry the batches according to the sequence assigned to the specific process, its priority, and then the bath condition.
  • Possibility to change the technological parameters during the work in automatic mode (time for process tanks, bath temperature, drip time, the parameters of transporter movements, etc.).
  • The lock of particular process tanks and the possibility to choose the option of batch processing.
  • Alarm system controlling the correct work of all elements and preventing the negative consequences of emergency situations.
  • Statistic functions (e.g. load meters, surface meters, ampere-hour counting, chemical additives usage, drive working hours etc.)
  • Savings on electrical energy through controlling the bath heating due to weekly schedule defined by the user and by keeping the minimum bath temperature while the line is stopped.
  • Savings on electrical energy due to application of high-frequency, digitally-controlled and highly efficient rectifiers.
  • Possibility of implementing any kind of communication protocol in order to cooperate with third-party devices (rectifiers, scales, displays, label printers).
  • Communication with other control systems and data exchange through the Ethernet.
  • Remote access through the Internet to controllers’ visualization, diagnostics, data reports. Due to the remote access function line servicing time is reduced to a minimum.
  • Advanced diagnostics of PLC controller through website. The user has not only the access to information about software and hardware from any location worldwide but can also use ready diagnostic applets which can be easily integrated with the application.
    All functions necessary for line monitoring can be activated from any PC computer without installing any additional software. While servicing, it is possible to offload the data from the controller and save it to a file simply with a mouse click. In more difficult cases, this allows for an offline data analysis in next steps of technical support.

 

3 igal stronaglowna

 

Extensive visualization software - intuitive operation

  • Visualization on colour touchscreen panel, giving the full picture of the line and process course. The main screen presents lines, transporters and other devices (rectifiers, heating, pumps, etc.).
  • Stations: batch, recipe, specified/actual time, drip time, options of load processing, rectifier’s current set-point, heating parameters, etc.
  • Transporters: current transporters position, work mode, load condition, sensors and actuators status
  • Heating: set-point/ actual temperature, work mode’s selection, manual control mode, automatic date/hour activation set-point, diagrams with course of temperature over time.
  • Rectifiers: remote / actual current, work mode’s selection, manual and automatic control mode, Ah counters, diagrams with course of temperature over time.
  • Dispensers: counter setting (Ah counter’s or the surface) and dose setting (specified in [s] or [ml] when the counter’s set value is exceeded, work mode’s selection, manual and automatic control mode.
  • Logging system: user login and control of the access to various functions of the programme. Each of the users has the access to selected functions.
  • Alarm system: monitoring the correct work of all line’s devices. In case of failure there is an error message shown on the screen together with the time and date of the registered damage. Alarm history allows to scan the list of confirmed failures.