The Need for Automation - Part II

Feel welcome to explore the future with us as we progress towards a fully automated extrusion line. Which modules can aid in automating the extrusion process, enhancing product quality, and boosting efficiency? Furthermore, what significance do inline process measurements hold in this context?

The subsequent "foundational elements" are crucial in their function:

Intelligent control systems

Integrated control systems that can operate the extruder, melt pump, polishing unit, and downstream equipment in combination facilitate the overall control of the system.

Automated cleaning systems

In addition to modules that facilitate semi-automatic cleaning of the extruder and the tool – especially crucial in PVC processing.

Systems for stabilizing pressure

We are considering solutions to minimize pressure fluctuations in twin-screw extruders, resulting in enhanced semi-finished product quality.

Gravimetric dosing and blending systems

Modules like the SAVEOMAT series from iNOEX accurately regulate the material input into the extruder by weight rather than volume, playing a crucial role in ensuring the consistency of material feeding.

Integrated inline measurement systems

These could facilitate dynamic control of line or take-off speeds based on real-time data.

Automated extraction systems

Special haul-offs with anti-pinch sensors and independently driven tracks ensure precise control of the extrusion process.

Surface inspection systems

Modules like AllRounDia DV or ProfilControl 7 Surface Tube from PIXARGUS facilitate the seamless monitoring of product characteristics and identification of imperfections like scratches, streaks, gels, and stains.

Modules for data analysis

Modules like the Industrial Data Manager by iDOO facilitate efficient, automated, and user-defined assessment of gathered process data.

Integrated communication interfaces

OPC UA interfaces and MQTT protocols facilitate seamless communication among various system components.

Animated user guides

Animated videos in the control system aid operators and simplify the management of the intricate system.

Inline process monitoring

Another crucial element for the dynamic management of extrusion processes is inline process measurements, which primarily encompass the following parameters:

• Real-time Data: Inline measurements continuously offer real-time data on the current process status, allowing for immediate response to deviations or changes in the process.
• Precise process control involves continuously monitoring critical parameters to enable precise and dynamic control of processes. Deviations can be promptly detected and corrected.
• Automation: Inline measurements are fundamental for automated control loops, enabling automatic adjustment of control variables based on measured values without manual intervention.
• Quality control: The ongoing monitoring of product characteristics throughout production ensures a consistently high product quality.
• Enhanced efficiency: Precise control allows for optimal resource utilization and minimizes waste, resulting in improved process efficiency.
• Early error detection enables the identification of deviations or disruptions in the process before they result in quality issues or failures.
• Flexibility: Inline measurements allow for the flexible adjustment of process parameters to accommodate changing production requirements or material properties.
• Process Optimization: The acquired data can be utilized for ongoing enhancement and optimization of processes.
• Traceability: Comprehensive documentation of process parameters guarantees full traceability of production.

In summary, inline process measurements are crucial in dynamic control, offering real-time data to precisely, flexibly, and efficiently control and optimize processes.

The circle is completed by optimizing product quality.

By gathering real-time data during the complete production process, discrepancies can be promptly detected and rectified before causing quality issues. This necessitates ongoing monitoring. Accurate process management and the consequent continual measurement facilitate highly accurate and responsive regulation of the process variables, resulting in consistently superior product quality.

In the realm of early error detection, identifying deviations or faults in the process at an early stage is crucial before they impact the final product's quality. This early detection leads to waste reduction. Detecting and rectifying deviations promptly minimizes waste, enhancing production quality and lessening environmental impact. A mutually beneficial outcome!

Utilizing inline measurements enables the manufacturing of products within stricter tolerance limits, enhancing precision and quality. The acquired data can be utilized for ongoing process enhancement, ultimately enhancing product quality. Continuous monitoring enhances transparency in the production process, facilitating improved process and product safety.

Inline measurements facilitate quick adjustment to evolving production needs or material characteristics, thereby guaranteeing the quality of various product types.

100% control

Unlike random sampling checks, inline measurements using products like AUREX, WARP, or iXRAY from iNOEX allow for a thorough examination of all manufactured units, ensuring the overall production quality.

Intelligent sensor technology from 2pi-Labs, measurement system intelligence from iNOEX and PIXARGUS, and optimized process engineering through data science from iDOO are essential components for advancing technical progress in the realm of highly precise extrusion products.

Inline process measurements significantly contribute to ensuring high product quality and driving continuous improvement.