contact details:
tel. +48(42) 616-23-00
fax. +48(42) 616-23-49
System Purpose
Three Conveyor Belt Production Lines in SEMPERTRANS Bełchatów were fitted with Automation System GUTMER in 2003. The System enables full service of conveyor belt production process. The production line consists of belt preparation system, vulcanization press, drawler and coiler. The basic GUTMER System functions include:
- Press units' work monitoring and control,
- Drawler and coiler's work monitoring and control,
- Maintaining of the monitored technological process parameters on a given level,
- Execution of units' work determined by the technology of sequences,
- Visualization of the monitored units' state,
- Visualization of the monitored analogue values
- Unit's failure states visualization,
- Archivization of the monitored analogue values' time functions,
- Operational routines monitoring,
- Unit, operational and alert events archivization,
- Collaboration with the Production Management System Promis S4.
Operating of Vulcanization Press
Press control includes:
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- Maintaining heating panels' temperature during the technological process with tolerance ±0.5°C on the whole surface (2.5m x 10m), except for the “cool ends”,
- Pressing pressure adjustment within the range up to 400 bar,
- Maintaining pressing pressure during the technological process with tolerance ±2 %,
- Process time adjustment,
- Belt's length measurement with accuracy ±0.5mm/1m,
- Data logging and visualization of whole technological process as well as particular temperature and pressure time functions,
- Collaboration with the Control Systems of the Production Line's parts “A” and “B” and with part “D” control system.
Operating of Drawler and Coiler (part “D”)
Drawler and coiler control includes:
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Control of the coiler's drive in correlation with the broaching machine – maintaining constant tape tension force during the whole reeling cycle with tolerance ±5%,
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Collaboration with the control units of the technological process line's parts “A” and “B” as well as with part “C” control unit.
System Structure
The System has a hierarchical structure in which two layers – Process Layer and Supervisory Layer – can be distinguished. The Process Layer realizes tasks directly connected with the technological process maintenance, whereas the supervisory layer supervises production process and gives access to Process Layer's parameters.
In order to provide the correct communication between system components, the following data transfer protocols were applied: OPC NET8, Profibus DP and FMS as well as MPI. Profibus Protocol is used in communicating between PLC Controllers and Production Line Server (Profibus FMS) as well as between Drawling and Coiling System PLC Controller and Frequency Converters (Profibus DP). The NET8 Protocol enables communication between Application Database Modules and Database Servers while the OPC Protocol enables communication between Production Line Server and Dispatcher/Department Computer Workstations. The MPI Protocol provide the access to PLC Controllers information resources from Operator Consoles and remote access (DriveES additional unit) to PLC and Frequency Converters software (Teleservice).
Supervisory Layer
Supervisory Layer of GUTMER System consists of the following elements:
- Department Database Server (redundant),
- Department Computer Workstations (quantity depends on purchased licence),
- Dispatcher's Computer Workstations (quantity depends on purchased licence).
Department Database Server is responsible for collecting and storing data concerning process course (trends, alerts, events) as well as order realization parameters (set up and realized process parameters' values for each process cycle). Process data are transferred to Department Server through the Production Line Server (NET8 Protocol). Line Server provides buffering for the data collected by Process Layer. In case of temporary failure of communication with Department Server the collected data will be sent after communication restoration. The task of Department Database Server is also to act as an interface with Promis S/4 Production Management System.
Communication is done by means of NET8 protocol and indicated database tables, prepared for transferred data reception.
The Department Computer Workstation is designed for the Process Engineer with default application "Process manager". The profile of this application enable service of orders delivered by Promis S/4, creation and modification of recipes as well as process data monitoring. Person logged on this Workstation ascribes order, which is to be realized during the forthcoming production process, to Production Line. The Dispatcher's Workstation enables current service of Production Line work and is designed only for person in rank of Foreman - LIne Operator. The default profile of "Process manager" application contains screen used to give work permission to the Line Operator, according to the Process Engineer order. There are also other screens available, which enable monitoring current and archival values of process variables.
Despite functional isolation of Process Engineer and Dispatcher's Workstations, "Process manager" application enables flexible modification of each profile privileges. It is also possible to log interchangeably on both Workstations – the profile is associated with a particular system user (Dispatcher, Process Engineer) and not with workstation hardware.
Process Layer
All devices of Process Layer are localized in the production room, in the neighbourhood of controlled processes. The main tasks of Process Layer are as follows:
- Picking up the process signals,
- Press units' monitoring and control,
- Drawler and coiler's work monitoring and control,
- Production realization according to a recipe received from the Production Management System,
- Local visualization of controlled units' state.
Considering the area of the controlled processes, the following Operator Panels were installed:
- Press Operator Panel,
- Drawling and Coiling System Operator Panel.
The Press Operator Panel consists of:
- PLC Programmable controller – Simatic S7-400,
- Operator Console with graphic screen,
Drawling and Coiling System Operator Panel consists of:
- PLC Programmable controller – Simatic S7-400,
- Operator Console with graphic screen,
- Two frequency converters – Masterdrive VC (CUVC)
The main element of both panels are PLC Controller. The Controllers carry out direct tasks of monitoring and picking up the process signals. The visualization of process is possible due to Operator Consoles, placed close by Production Line. The task of Frequency Converters is to supply power to drawler and coiler's motors with smooth adjustment of controlled process parameters, i.e. belt feed velocity and constant tension force. In Frequency Converters special software script was applied (Script MC_Winder_Indirect – Control Method B, modified and aided by PLC controller). The script calculates the constant tension force on the coiler with any feedback signals (without reading of the actual force value and the current diameter of the ballot with reeled or unreeled belt). The Process Line Server is the Process Layer element responsible for communication with the supervisory system. The information from the process is read by Process Line Server from the PLC Controllers which are the data source for the Supervisory Layer. The information determining and defining parameters for the realized process is stored in the PLC Controllers by means of the Process Line Server.