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PROCESS CONTROL | DIGITALISATION


Right: Coperion’s ServiceBox is being used alongside other digital tools to allow secure remote support up to full line


commissioning


procedures, were examined in detail,” says Markus Schmudde, Head of Research & Development, Compounding & Extrusion at Coperion. The new GUI uses a


simple, intuitive touchscreen design that won an award in the product interface catego- ry in the 2021 iF Design competition. The touchscreen uses high-contrast icons to control extruder functions, with other operating functions such as recipe administration integrated into the control. Torque and throughput can be controlled intuitively using slider controls that are ergonomi- cally positioned on the lower display edge while activities such as extruder start-up sequence can be visualised step by step. A modularly-constructed machine image allows


the operator to access every section of the machine on screen and expand the amount of information as needed. The user can configure a dashboard to display current values of key parameters in a detailed view, while a distance view allows the operator to see the remaining production batch run-time and to determine whether the machine needs any intervention without approaching the control panel using colour-coded status indicators. The control also uses a responsive design, which means that the view automatically adjusts to any screen size for use on tablets, for example. In addition to alarm-based handling recommen-


dations and process monitoring, another ‘Smart Machine Feature’ incorporated into the control system is predictive maintenance based on diagnostic data. Technologies that create transpar- ency for the tasks and the process on the shop floor will pave the way for more advanced analysis, which will show what can be changed to have greater productivity with less process risk, suggests Schmudde. In addition, benefits can be gained with wider integration. The CSpro control is compatible with OPC


Right: A number of Industry 4.0-inspired data tools are included in Entek’s new HT72mm


compounding extruder


20


40084, an open interface for communication that allows it to be readily integrated into other systems, such as manufacturing execution systems (MES) or order manage- ment systems. Schmudde says the OPC UA standard has been jointly established by the umbrella organisation of the European Plastics and Rubber Machinery Manufactur- ers Association (EUROMAP), the German


COMPOUNDING WORLD | August 2021 www.compoundingworld.com


Mechanical Engineering Industry Association (VDMA) and leading machinery manufac- turers for the plastics industry.


In the coming years, Schmudde anticipates increasing integration up and down the supply chain between plastic processors, their technology suppliers, and their customers. “And we expect a much closer interlinking of internal


departments and processes of plastics compound- ers—all with the aim of increasing product quality, throughput and optimisation of flow of processes and overall equipment efficiency,” he says.


Remote service An Industry 4.0 tool that began to see much broader use during pandemic travel restrictions was the ability to link remotely to machines to provide troubleshooting and maintenance, and even to support installation and start up. Originally devel- oped to provide secure remote maintenance in 2010, the Coperion ServiceBox was used last year to modernise a ZSK 250 extruder at a customer’s facility. The project proved that the concept of remote machine commissioning could be successful. Schmudde says Coperion currently uses a


variety of tools — including ServiceBox, augmented reality, and virtual meetings — for remote work but he cautions that security is key. “Smooth implemen- tation is an important goal for us, which is why we often use tools that our customers are already familiar with and that the IT infrastructure at our customers’ sites allows. Any unproven technology can open doors to cybercrime or other risks that must be avoided,” he warns.


Integrated control A range of Industry 4.0-inspired data collection and process control tools have been integrated into Entek’s HT72 high torque co-rotating twin-


IMAGE: ENTEK


IMAGE: COPERION


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