Customer Solutions
Using NI LabVIEW and PXI to Enhance High-Temperature Production of a Pyrex Glass Press Instrumentation System
Author(s):
Thomas B. Jozwiak, Data Science Automation; Christopher D. Olson, Data Science Automation
Industry:
Machines/Mechanics
Product:
LabVIEW, PXI/CompactPCI, Signal Conditioning
The Challenge:
Upgrading a process monitoring system with enhanced features for high-temperature production glass presses at Pyrex, a glassware manufacturer.
The Solution:
Developing a contemporary system based on NI LabVIEW, PXI, and DAQ products to acquire digital and analog signals from displacement sensors, pyrometers, and other sources for event and process monitoring and replicate the original GUI to simplify the transition for our customer.
Creating a System that Sustains Harsh, High-Temperature Environments
At Data Science Automation (DSA), we built an industrial PXI solution for Pyrex, a glassware manufacturer, suitable enough to sustain a harsh, high-temperature environment and 24-hour operation. In addition to real-time analysis and display of process characteristics, the system collects data for archival to a networked Oracle database.
The PXI solution utilizes a mixture of analog and digital inputs to monitor the glass press process and compare the analyzed values to stored parameters for several types of glassware. This is critical to the quality of the glass for the operator to have immediate access to the analyzed data for adjustment of the process if necessary. This proves especially true during change of production runs. Running outside of these specified parameters leads to possible loss of product and delays in the production cycle.
Because the operators are accustomed to viewing the results with the current system, the new solution would need to present the data in a similar manner. With LabVIEW, we developed front panel controls and indicators that closely resembled the old systems but have all the new, built-in features to design a useful user interface.
The system permits selection from several existing job files (recipes) that specify target values, ranges, and more for various pieces of glassware. These recipes have been established from the years of production of several different types of glassware. Production rates range from 20 to 50 parts per minute. Manufacturing new designs and storage of the new recipes is easily accomplished through a spreadsheet recipe interface.
Simplified Acquiring and Exchanging of Signals
Several signals from the press are acquired from sensors, and event-timing signals are exchanged with the PLC, which controls a hydraulic ram for pressing the molten glass into the glass molds. In addition to the parameters displayed to the operator in the control room, critical values, such as mold temperatures, ram velocity, and event timing need to be displayed for the operators directly by the glass press. This is accomplished by outputting the analyzed data to an easy-to-see panel located next to the press. During the change to another piece of glassware, the operator monitors this critical subset of parameters at the press for adjustment of the process. Once the operators are satisfied with the quality of the glassware being made, they can better monitor the production from the local control room and select more detailed displays of the press activity by way of a selection of front panel screens.
The production line is located in a different area of the facility than the engineering and administrative offices. Leveraging the built-in features of LabVIEW, supervisors can view and even control the application with the built-in Web server. If a supervisor’s support is required on their off shift, they can remotely access the same control with a Web browser.
The data is acquired, analyzed, and presented to the operator and additionally logged to the local hard drive.
At scheduled intervals, the data is then inserted into a networked Oracle database using the LabVIEW Database Connectivity Toolset. Once the data has been archived in the company’s enterprise system, all personnel with access to the database can utilize it for reporting, production analysis, and report generation.
This is the first phase of the project. The next phase is to instrument the other four glass presses with the same type of solution. All the stations will be networked so data and recipes can be shared between them if necessary. In addition to all presses having their own DAQ system, one spare unit will also be used as a replacement should the need arise. The spare unit will be on the shelf and powered up, so it will be up to date with the information stored on the production presses. Should the customer desire to include additional channels, such as pressure, temperature, the PXI/SCXI chassis easily can accommodate several modules for expandability.
An Industrial Solution with the Needed Functionality
We used the modularity of the NI PXI chassis to deliver an industrial solution with the functionality needed by the customer. The ability of the NI product line to seamlessly connect to the customer’s service-proven sensors proved critical to this solution. By selecting the LabVIEW development environment, we easily could reproduce the capability of the existing system and introduce the new needed functionality need by our customer. The application is now structured in a modular-type architecture that will allow for easier future enhancement. The customer also benefits from the easy-to-follow application code as compared to the proprietary C-based code that was a challenge to understand and modify. Equally as valuable is the knowledge that the components are industry standard and available off the shelf for replacement if necessary.
For more information, contact:
Christopher D. Olson
Data Science Automation
Thomas B. Jozwiak
Consultant, Measurement & Automation
Data Science Automation
400 Southpointe Blvd., Ste. 210
Canonsburg, PA 15317
Tel: (724) 745-8400
Fax: (724) 745-8461
