Abstract
Manufacturers spending a lot of time for researching on better productivity and quality as competition on coating business is increasing in recent years. A successful research without a good track record of current production is not possible.
Besides we are in the middle of the fourth industrial revolution and all manufacturers should adapt to Industry 4.0 at one point. This all requires digitalization of wet grinding process as the main process of the plants.
1. Introduction
Wet grinding is a demanding process! Machine are operating with the smallest beads, high flow rates and maximized power introduction, the equipment increasingly performs at the highest possible capacity.
To keep a sustainable high performance, the automation solution must provide a high process control and continuous observation of important process parameters.
2. SmartPro
SmartPro™is Bühler’s solution to digitalize the wet grinding process to achieve higher traceability, better process control and benchmarking, which results in significant optimization of the production. Bühler see the development evolving as 5 stage. (Figure 1.)
Figure 1. Bühler’s 5 stage development of SmartPro – digital services
2.1. Smart Automation
Premium and Premium Plus control systems are first stage of Bühler’s digitalization. (Figure 2) It is a firstclass solution with PLC and touchscreen. A new user interface with PLC programming and touchscreen allows easy and intuitive operation of the machine.
The job-related analysis and diagnosis of the operating data informs the operator about the machine status. It has certain benefits for the industry:
1. Intuitive design for maximum productivity. The intuitive design and user guidance simplify the correct operation of the machine. The control is easy to use which makes extensive trainings unnecessary.
Additionally, a walk by screen with color coding shows warnings and standstills at a glance even from a distance.
2. Ideal handling of product/machine for optimal profitability. With Bühler control systems the machine can be used to its full extent. An intelligent cockpit shows.
Current process parameters including the optimum range of operation, which allows immediate adjustment. Further features, such as a job wizard, support the correct and fast start-up of the machine.
3. Auxiliary features for higher process reliability. Integrated recipe assistants allow a production process with enabling an ongoing adjustment of process parameters to the changing product characteristics. The result is higher process reliability in less time.
4. Elaborated data management for quality assurance. The control system uses intelligent data management for quality assurance and optimization. The user is able to access the past 200 jobs allowing replication and traceability of the production.
Additionally, in order to preventively maintain the machine, the occurring errors are tracked and ranked. This allows an easy scheduling of maintenance.
5. Remote access for easy process monitoring. The Premium Plus solution gives remote access to the control system, which greatly improves process monitoring. Standstills are detected more quickly and can potentially be resolved without being on site.
This saves costs and increases productivity. When required, Bühler Customer Service representatives can remotely access the system ensuring quick and inexpensive servicing.
Figure 2. Main main screenshot of a premium control HMI
2.2 Smart Visualization
Smart visualization’s target is to make machine data available for you anywhere and anytime. Operator’s or even top management can always check machine’s actual values as well as trends by their tables or even mobile phones.
Furthermore, remote access and control is also possible depending on user permissions. One can even set alarm values by this tool and will be warned by SMS and/or e-mails. A screenshot of the SmartPro cockpit can be seen on Figure 3.
Figure 3. A screenshot of the SmartPro cockpit
2.3 Smart Statistics
You can analyze your machine data and use it to optimize the production process. Like you can use your smartwatch to improve your running. At this stage; long term statistics, internal benchmarking, industrial benchmarking and data export will be possible.
2.4 Smart Machine&Plants
At this stage all machines and even plants will be connected to each other through cloud. The machine will continuously checks it parameters and improve the process parameters by optimizing the production.
3. Conclusion
You must be able to rely on your processes. They need to run smoothly and handle countless demands, such as for maximum product safety, efficient energy use or easy operation. As a solution provider with decades of experience in automation, Bühler sets industry standards and delivers the highest possible quality. All these digitalization has certain benefits for the industry:
1. Higher productivity,
a. Increasing uptime,
b. Shorter reaction time for maintenance,
2. Reduced costs,
a. Avoiding unnecessary maintenance visits,
b. Reduction external maintenance costs,
3. Quality assurance,
a. Production traceability&documentation,
b. Reduced claim cost from your customers,
4. Process safety,
a. Prediction of possible failures,
b. Early detection of abnormalities.
Aybars Kaya - Area Sales Manager (Turkey), Grinding and Dispersion Unit Bühler Satış ve Servis Hizmetleri Tic. Ltd. Şti. (Bühler Turkey)
