Customer SolutionsBridgeVIEW Expert System Improves Batch Processing Efficiency
Author(s):John Van Doren, Signature Control Systems; Tim Erickson, Signature Control Systems
Industry:Oil and Gas/ Refining/ Chemicals
Product:Compact FieldPoint, Data Acquisition, Distributed I/O, FieldPoint, Signal Conditioning
The Challenge:Improving process time and quality in batch processing.
The Solution:Using National Instruments BridgeVIEW to determine the process chemistry and adjust the process in real time for increased productivity and profitability.The The majority of batch and discrete processing done today is controlled via a fixed “recipe” based on empirical studies of the process variables and chemistry. Because of the variability in raw materials from batch-to-batch, environmental effects, and other processing conditions, “fixed process recipes”must be overly conservative in an attempt to accommodate all of the inherent process variables. This results in a compromise in both process time and quality. Signature Control Systems (SCS) Intelligent Process Control™ technology fills this gap in efficiency and quality by sensing the state of the process chemistry and adjusting the process in real-time. The resulting intelligent control solution delivers:
The Intelligent Control Solution SCS Expert Systems are based on the use of a proprietary impedance sensor technology that users can correlate with the actual chemistry of the process. Our patented technology has broad applications and can be used with any nonmetallic batch or discrete process in which there is chemical or phase change. The economic benefits of using the technology include improved productivity, ROA, and profitability, and a reduction in work-in-process.We are currently marketing turnkey, integrated systems for engineered rubber, wood, and plastic products. Users apply built-in algorithms with the Expert System software module to recognize certain features of the impedance signature and to apply the appropriate “process rule” associated with that feature. Users can correlate each feature of the signature to specific chemical and/or physical changes or states in the process. This is accomplished by comparing the two elements of the material’s impedance response (conductance and capacitance) with expert knowledge of the process chemistry. The conductance changes in response to changes in ion mobility in the material, and the capacitance changes in response to changes in dipole movement. The software includes cure recipe management using ODBC, PID control loops, historical trending (complete with multiple y-axis), alarm management, and automatic control logic.With BridgeVIEW, we created an application that can be applied to several process environments with a minimal amount of modification. Other benefits include a reduction in operator training and documentation costs and increased productivity and profitability. Wood Products Case Study Engineered wood products such as plywood, particle board, and oriented strand board are typically cured under pressure in multiplaten presses using thermoset adhesives. The typical lot-tolot variations associated with the adhesive systems used in the processing of wood products and the large variation in wood species and moisture content challenged us in developing an expert system.We were also challenged to isolate the sensor response caused by the adhesive from the strong sensor response of the moisture as it is converted into steam in the molding process. The accompanying graph shows an actual impedance signature for a laminated wood process such as plywood. In this case, we were able to isolate the moisture response with the conductance response of the sensor, and the response of the adhesive with the capacitance response of the sensor. The rule base for this process looks for the dissipation of entrapped moisture and the degree of cross-linking of the adhesive material before initiating the opening of the press and beginning to load the next batch of material. Engineered Plastics Case Study Engineered plastics are used in a wide variety of applications, including aerospace, automotive, agriculture, sporting goods, and electronics. They are typically processed under pressure and at elevated temperatures using autoclaves, or via injection, compression, or resin transfer molding. By measuring the dipole movement and resin, we pinpoint the “signature” curve of the plastic and therefore intelligently control the process. For more information, contact: Signature Control Systems Tel: (303) 783-0500 Fax: (303) 783-0800 E-mail: sales@signaturecontrol.com Web: www.signaturecontrol.com
View the entire user solution in Adobe Acrobat PDF format. |
