In last month's issue, the productivity improvements experienced by Prosoco were discussed. In this issue a well-known airconditioning manufacturer opts for a system based on the Rockwell Automation Logix architecture.
Trane tries SoftLogix
While Prosoco integrated its new plant based on the capabilities of ControlLogix, similar integration of control and information is achievable using the PC-based SoftLogix control platform.
As a first step to plant-wide integration, Trane Company, a well-known air conditioner manufacturer with a plant in the US, focused its redesign efforts on its spine-fin wrapping operations. Plant engineers sought to collect production data from each of the plant-floor's 60 spine-fin wrapping machines, then compile and display that data in realtime for machine operators. Ultimately, the data needed to appear in HTML format for posting on Trane's intranet, where management could closely track production progress.
"Increasing our overall production levels is one of our biggest goals," said Paul Milwood, a Senior Principal Engineer at Trane. "If we could increase the plant's spine-fin wrapper production section, we could ultimately achieve increases in overall production efficiency."
Each of Trane's 60 spine-fin wrapping machines wraps and glues a 12,7 µm by 25,4 mm band of ribbon around a 3/8" pipe that runs up through the centre of the wrapping machine. The finished product is a continuous length of pipe with a ribbon 'edging' fanning out perpendicular to the pipe (similar to the fanned edges on a car's radiator).
Under the old system, analog counters measure the linear amount of wrapped pipe produced by each machine. Each spine-fin wrapper is manually controlled, with individual control panels installed near each machine. The challenge was to modify this system to capture and compile production data, then use that data to increase production plant-wide.
Integrating with soft control Trane hired Tegron, an East Texas control system designer and authorised Rockwell Automation Solution Provider, to design and install a new control system that would address the company's information-gathering needs.
Although Trane's specifications could be achieved with standard PLC-based control, Milwood and Tegron President Steve Voelzke agreed that a PC-based system could better handle the extensive data-management requirements. Voelzke recommended the Allen-Bradley SoftLogix controller as the best control product for Trane's systems, and as a key element in integrating sub-manufacturing processes in the plant.
The new SoftLogix system will control operations for each of the 60 spine-fin wrappers, which will be joined together using the Rockwell Automation NetLinx communications architecture. The SoftLogix controller will also compile and transmit production information to a Trane engineering department server running the Microsoft SQL database.
RSSql and RSBizware Historian will manage the information transactions while tracking production. Using an Oracle-based web server, users will be able to access production information through individual web browsers.
Allen-Bradley PanelView 300 monitors stationed at each bank of wrappers will give operators easy access to system data. Display interface functionality will be handled by Rockwell Software RSView32 software. RSView can provide a consolidated view of the status of all wrappers, and can reside on the same PC as the SoftLogix controller.
Once Tegron installs the SoftLogix-based system, production operators will track the uptime and downtime of every machine, enabling them to identify and correct any problems. They will also be able to track production trends and know how many metres of spine fins are available for assembly in other parts of the plant. This is expected to boost overall productivity, as all sections of the plant are integral to final assembly.
System engineers will conduct the system installation and control changeover without any downtime for the plant's spine-fin wrapper section. Tegron expects to complete the Trane system upgrade by summer. Eventually, Trane will wire other sections of the production plant and pull them into the control/information loop.
Both Prosoco and Trane have capitalised on the benefits and successes of merging control and information. When paired with the Logix architecture, plant-wide information and ERP systems give managers a realtime window on plant production, including scheduling, production rates, inventory, labour hours and downtime. Such information allows managers to quickly respond to custom orders and set up custom production runs, thereby achieving significant operational benefits.
Rockwell Automation
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