Monitoring and Controlling Automatic Mixing and Dispensing Machines
As technology advances, textile manufacturing has been transformed from a labor-intensive to a partially or fully automated industry. Automation is significant in all segments of textile production - from spinning to printing, and textile machinery manufacturers are constantly searching for new technologies and automation processes will increase the productivity of their machines. The color paste mixing and dispensing machine is an essential part of the printing and dyeing process. With the advantage of automatically computerized controls and database management, the system can significantly improve its dispensing precision, working efficiency and production quality as well as reducing material consumption.
AdvantechFounded in 1983, Advantech is a leader in providing trusted innovative embedded and automation products and solutions. Advantech offers comprehensive system integration, hardware, software, customer-centric design services, and global logistics support; all backed by industry-leading front and back office e-business solutions.
- CONNECTIVITY PROTOCOLS
Our customer's automatic mixing and dispensing machine comprises of a mixing head, an electronic weighing scale, dosing station, color paste mixer, mother liquor storage tank and delivery pipeline, and automatic conveyor. They used to use a tablet PC as their system control device, but the high operating temperatures (over 50℃) usually cause system failure and computer crashes. As a result, production was delayed and raw materials were wasted. Therefore, they decided to purchase a new fanless device which has to be operated over a long period of time, especially in higher temperature areas. At the same time, its CPU and memory specifications needed to meet the requirements of the bespoke software. Due to a trade-off between hardware specifications and cost control, and after our professional assessment, our customer changed their original requirements to accept Advantech’s economic program. Our total solution with a UNO-2173A fanless computer, ADAM-4520 isolated converter and ADAM I/O modules not only completely integrates the data acquisition and control functions, but also supports a wide operating temperature range (-20 ~ 70℃) with high performance. The UNO-2173A can fully master the on-site operation through the ADAM-4520 to convert RS-232 signals into isolated RS-485 signals; even when the operating temperature exceeds 50 degrees, the CPU can run smoothly. In addition, the ADAM-4520 allows users to easily build an industrial grade and long distance communication system. As for the ADAM modules (ADAM-4117, ADAM-4018, ADAM-4015, and ADAM-4024), they are connected to the peripheral facilities to acquire the on-site signals and data. The robust ADAM-4117 analog input module is capable of measuring the voltage and current. The ADAM-4018 thermocouple input module and ADAM-4015 thermal resistance module - are in charge of the temperature measurement. In addition, the ADAM-4024 module provides the analog output to control the heater. All of them are designed for reliable operation in harsh environments. Technology Deployed: UNO-2173A: Intel® Atom® N270 Processor Automation Computers with 2 x LAN, 3 x COM, Mini PCIe ADAM-4520: Isolated RS-232 to RS-422/485 Converter ADAM-4117: Robust 8-ch Analog Input Module with Modbus ADAM-4018: 8-ch Thermocouple Input Module ADAM-4015: 6-ch RTD Module with Modbus ADAM-4024: 4-ch Analog Output Module with Modbus
- DATA COLLECTED
Downtime, Machine Performance, Machine Utilization Rate, Material Volume, Precision
- SOLUTION TYPE
- SOLUTION MATURITY
Mature (technology has been on the market for > 5 years)
- OPERATIONAL IMPACT
Impact #1 [Efficiency Improvement - Productivity]
Significantly reduces system malfunctions (almost zero failure rate)
Impact #2 Impact #3
- QUANTITATIVE BENEFIT
Cutting their purchasing cost by 50%
- USE CASES
Machine Condition MonitoringMachine condition monitoring is the process of monitoring parameters such as vibration and temperature in order to identify changes that indicate a reduction in performance or impending fault. It is a necessary component of predictive maintenance solutions and allows maintenance to be scheduled prior to failure, or other actions to be taken to prevent damages to the machine and loss of production. Condition monitoring also provides value beyond improving maintenance schedules. For example, improved visibility into machine operations can indicate the root causes of product defects and can support optimization of energy consumption.