Product category:
HMIs/Operator Interfaces
News Release from: Siemens Automation and Drives | Subject: TP170M HMI
Edited by the Engineeringtalk Editorial
Team on 31 May 2005
Flexible HMI system upgrades plastics
processing
An integrated control solution reduces build and commissioning time while increasing operational flexibility for plastics recycling machine manufacturer Plasmac.
When plastics recycling machine manufacturer Plasmac, based in Aylesbury, was looking to upgrade its entire product range, the company turned to Siemens Automation and Drives for an integrated control solution that would reduce build and commissioning time, while increasing operational flexibility Plasmac's ranges of recycling extruders are designed to meet with the varying demands of the thermoplastic industry to convert plastics scrap into a high quality reusable granule
For the plastics manufacturing sector, recently crippled by the rocketing prices of resin and polymers, recycling waste material is becoming critical for survival.
Plasmac's technical team looked at the various turnkey solutions on offer to fit their requirements but decided to opt for a bespoke design route using a control system that included HMIs as standard on all machines, unlike any of the competitors.
The Siemens solution was chosen due to its flexibility and ability to supply a competitively priced system, with improved diagnostics, remote monitoring, simple integration and worldwide backup service.
Using WinCC Flexible HMI software, Plasmac achieved high functionality on a low-cost HMI touch panel.
Creighton Varney, Technical Manager at Plasmac was then charged with the task of integrating the system into the complete machinery range.
The original combination of relay logic controls and standard switchgear previously provided limited control functionality and resulted in extended build time.
The integrated Siemens solution has revolutionised the way Plasmac manufactures and in turn, the way the company's customers recycle.
The seamless package has been applied to the whole range, with machine control systems sharing one generic configuration, rather than multiple platforms, increasing standardisation.
This was made possible because the TP170M HMI has no footprint, enabling Plasmac to incorporate an innovative backplate design that spreads across the width of the control panel.
With just one cable to plug in, using a single standard facia, wiring on one example system has been reduced from five days down to three and a half.
Commissioning has also seen significant improvements, with most of the parameters established within the PLC, very little manual input is necessary.
Operator training, an often time consuming process is greatly improved due to the multi language format that the TP170M supports.
The benefits to end users are numerous, a password protected user operation system with limited access to specific control areas, simplifies operation, and increased diagnostic functionality, provides specific locations to a fault within the machine, saving both time and money.
The Siemens solution is based around the S7-200 PLC and an EM231 thermocouple module.
MicroMaster 440 inverters are controlled over an RS485 network (USS) and are connected via Profibus cabling supplied by Underwoods Electrical Distributors.
"Working with Siemens gives us the benefits associated with the commonality of components, systems integration with Scada systems, and increased security of sensitive parameters", said Varney.
Remote diagnostics is available through the installation of a modem module.
The plug in and play capabilities of the HMI screen means that in the case of a catastrophic failure, replacement components can simply be shipped to location and connected without the requirement of a service engineer.
With customers across the other side of the globe in countries like Australia, flying an engineer onto site to resolve a problem can prove highly expensive.
"98% of our sales are exported to companies across the world, having global support and remote diagnostic capabilities was a big plus point for us", added Varney.
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