Customer Solutions
National Instruments Lookout Controls Entire Manufacturing Process
Author(s):
James Caruso, Superior MicroPowders
Industry:
Oil and Gas/ Refining/ Chemicals
Product:
Compact FieldPoint, Distributed I/O, FieldPoint, Lookout
The Challenge:
Manufacturing high-performance powders for use in the electronic, display, energy, and specialty powder markets while following stringent quality and safety procedures.
The Solution:
Using Lookout software to control and monitor the entire manufacturing process.
Introduction
Superior MicroPowders (SMP) produces powders using a proprietary, continuous, non-material specific technology. Real-time data acquisition, process control, and sequencing are critical for our continuous process. We needed a system with highly robust and flexible process management. In addition, we needed to reproduce our specifications repeatedly to meet strict quality control procedures.
System Architecture
For each powder manufacturing unit, we monitor a total of 150 I/O points for relative humidity, temperature, flow rates of liquids and gases, pressures and density of fluids. We use Lookout to control gas and fluid flows, system temperatures, pumps, fans, and process sequencing. In other words, we have automated our process so it can operate solely with Lookout in control. Deciding to take advantage of industry-standard PCs, we use Lookout extensively for control, without PLCs. In addition, because we could get both hardware equipment and software from National Instruments, we chose both Lookout and FieldPoint products to complete our system. Several FieldPoint modules gather discrete, analog, and temperature data. All modules communicate together in a bank and feed data back into the PC for control by Lookout without the need for PLCs. With quality control and safety being our biggest concerns, the Lookout and FieldPoint combination is the perfect choice for our manufacturing process.
Moreover, we knew that in an industrial process, less than accurate process monitoring can result in damage to expensive equipment, dangerous operation conditions, and poor quality control. We chose National Instruments Lookout software and FieldPoint hardware because, through SPC, both products can intervene, correct the situation, and protect the equipment, personnel, and product quality. Lookout was the easiest to use and highest productivity product on the market. Because this is an entirely flexible process, we change and tailor processing parameters to customize and optimize our products. For this reason, we needed a truly flexible monitoring and control system. With Lookout, we can change source code on-the-fly without recompiling.
Manufacturing Process
Our manufacturing has many critical processing parameters that can be independently controlled to result in the fabrication of state-of-the-art powder products. We must have the ability to independently monitor and adjust a myriad of process conditions. Using Lookout, we have tight control over the key elements in the process. Also, startup and shutdown are critical steps in any manufacturing process. Therefore, Lookout monitors and controls the entire manufacturing sequence from startup, through fabrication, to shutdown and cleaning. This minimizes downtime, increases safety, reduces the chances of a system malfunction, and ensures product quality.
Operators are a key part of our manufacturing process. Lookout provides a simple yet powerful interface for operators to instantly ascertain the condition of critical process parameters. The built-in security and alarming functions keep operators and the process safe.
For gathering sensor data and outputting various control signals, we chose several types of FieldPoint modules for the process. For all our discrete outputs, such as pumps, we use the relay module, FP-420. We also use the FP-301 module with 24 V on/off signals, pressure switches, and level switches. We use the FP-110 module to monitor ananalog signals, such as flow meters or any other 4-20 mA signals. If we need analog control, we use the FP-200, which handles an output of 4-20 mA. Various temperatures are critical for use to monitor and control the system. We have K and S-type thermocouples and use the FP-120 module to gather temperature information. All modules communicate in a bank and send information back to the computer to be analyzed with Lookout. With our system, using Lookout and FieldPoint, we meet our three objectives:
About Superior MicroPowders
SMP manufactures powders using a proprietary powder production technology for electronic, display, energy, and specialty applications. SMPs powders have novel and advantageous properties that differ from conventional powders. SMP products have powder characteristics that include:
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Spherical morphology
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Micron-sized
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Controlled particle size distribution
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Controlled microstructure
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Non-agglomerated
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Excellent dispersability
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Superior rheology control
Because of these advanced powder characteristics, SMPs products offer many advantages to the customer. The powders’ spherical shape, small size, and lack of agglomeration allows for the fabrication of powder dispersions with excellent rheological behavior, leading to the deposition of fine and controlled features. These characteristics also lead to improved powder packing and maximized as-deposited powder performance. With SMPs ability to control microstructure, the fabrication of novel compositions, alloys, and composites with tailored porosity, crystallinity, and surface area results in superior powder performance.
For more information, contact:
James Caruso
Superior MicroPowders
3740 Hawkins NE
Albuquerque, NM 87109
Tel: (505) 342-1492
Fax: (505) 342-2168
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