With the PlantPAx DCS as a Higher-Level Process Control System, a "Smart Factory" Has Been Realized

Solution

The PlantPAx system is virtually predestined for sensitive applications, in which reliable around-the-clock operation is a requirement. This is due to the fact that this process control solution not only guarantees a high level of availability via the redundancy of system components, but also by means of a device level ring topology in the EtherNet/IP network.

"The major advantage of PlantPAx is that it acts across different disciplines and combines the different areas – i.e. the continuous furnace control and the batch plant – into a joint network. And devices that actually communicate over a different protocol, such as the electronic systems for weighing or the barcode reader, can also be easily integrated into the higher-level process control system," states Joachim Ullrich, visibly satisfied with an engineering-friendly solution which enabled ZIPPE to make an entire batch plant with mechanical equipment, conveyor belts, feed units, motors, worm drives, a large 4,000 liter mixer, and the entire automation technology, including control cabinets, fully operational in only one year.

"Shortly after we were awarded the order, Rockwell was there and actively supported us in the selection of the appropriate components and in the design of the plant network," remembers the Head of the Electrical Engineering and Process Automation Department at ZIPPE. "The final customer is very satisfied with what we have realized together," he adds, especially because enough reserves were planned and included on the system.

The first small expansion, to integrate an additional raw material weighing system into the PlantPAx, has already been implemented.

Results

The pre-furnace silo, that is, the silo upstream of the glass melting furnace, demands replenishment in a fully automated manner if a certain threshold value has been on the batch plant. The supplies of sand, soda and chalk are generally among the most important ingredients found in the production of glass and must be 100 percent according to the recipe.

The ZIPPE batch plants, however, need to potentially also weigh other ingredients – in some cases with to-the-gram precision. "Every single one of our customers has his own special and secret recipe, i.e. in which mixing ratio the raw materials are contained in his glass. The important thing is that the individual components are weighed most precisely and within a certain period.

This enables, for example, a new batch to be produced every four minutes," explains Joachim Ullrich. Consequently, in addition to the "calling signal" of the pre-furnace silo, the weight signal of the weighing vessel is one of the most important pieces of information processed by the PlantPAx distributed control system.

Furthermore, this higher-level intelligence ensures that the silos are loaded correctly. "With technical aids we exclude, for example, that sand ends up in the soda silo. By scanning the barcodes on the delivered raw materials, the control system sets the correct path. A wrong selection is then no longer possible," emphasizes the ZIPPE department head, highlighting a valuable feature that helps the final user avoid errors.

The PlantPAx DCS also shows itself to be very user-friendly when it comes to monitoring adjustable frequency drives. Drives are displayed on the visualization stations by means of icons and faceplates and managed on the asset management level.

In addition, disaster recovery functionality enables the system to automatically backup and restore the drive configuration as well as logging of changes. Extensive diagnostic information is delivered directly to the user on the HMI level.

"The PlantPAx Process Library contains ready-to-use control and diagnostic objects. This allows the entire production process to be easily monitored. Thanks to a seamless EtherNet/IP network structure, the technicians can route through right up to the variable frequency drives to retrieve individual variables or current signal states," says Joachim Ullrich, stating the benefits of the PlantPAx faceplates for diagnostics and maintenance. Alarm indication and parameterization are also simplified by the Process Library.

By utilizing PlantPAx as a higher-level process control system, a modern "Smart Factory" for the production of brown glass bottles and ampoules has been erected in France.

It is intelligently and redundantly networked via EtherNet/IP and offers real-time visibility on all the currently running production processes. It is simple to expand and offers a wide range of connection options. Thanks to PlantPAx, all operating stations exhibit a uniform look and feel and standardized icons for visualization purposes.

This reference project has entered into operation as scheduled. "We generally want to ensure that our customers can get started with the plants supplied by us as soon as possible. This is why we test all control systems in detail before they leave the company. We work with virtual production data, enter different recipes, produce thousands of batches and simulate, for example, an entire monthly production in order to avoid any ambiguities or errors in advance," reveals the Head of the Electrical Engineering and Process Automation Department at ZIPPE.

Well, PlantPAx has passed these tests with exceptional results. It is therefore no wonder that Joachim Ullrich is thinking of increasingly utilizing this process automation solution in ZIPPE's batch and cullet plants.

Allen-Bradley and PlantPAx are trademarks of Rockwell Automation Inc.