Plywood manufacturing plant automation with messung's nx-era series

The traditional plywood manufacturing process usually requires a large amount of manpower and produces a significant amount of waste material. Then there is the question of safety hazards associated with manually operated machines. Therefore, manufacturers are always looking for ideas that reduce dependency on manpower, improve efficiency and boost overall productivity.

Our client was no different. They approached Messung for a cost-effective solution to control their plywood processing plant.

ABOUT THE CUSTOMER

This customer is a reliable organization engaged in manufacture of a qualitative range of industrial products. They have a team of experts to maintain a vigil on the quality of the products. Every single piece of work is ensured with proper quality assurance. Use of modern technology, industry standards, timely and quality deliveries.

REASONS FOR AUTOMATING

Thereareseveralreasonsforautomating a PLYWOOD manufacturing system. Our client was keen to invest in automation for several reasons, namely:

• -increase labour productivity
• -reduce labour cost
• -mitigate the effects of labour shortage
• -reduce routine manual or clerical tasks
• -improve worker safety
• -improve quality
• -reduce manufacturing time
• -accomplish processes that cannot be done manually.

KEY SOLUTION GOALS

• develop a logic to control the process section-wise in the following sequence:

1. Raw material section
2. Dryer line section
3. Gluing and blending section
4. Forming and pressing section
5. Cutting section
6. Sanding section

• increase productivity and operational speeds
• improve system reliability
• reduce safety hazards for employees

THE SOLUTION

Working collaboratively with our client's team, the Messung engineering team proposed an automated solution that integrated:

• NX-ERA NX3020 PLC controller
• NX-ERA JET IO Modules
• NX-ERA NX5101 Modbus TCP remote IOs
• 10- and 7-inches HMI
• 26 nos. of VFDs
• control & synchronisation of VFDs on Modbus RS485 network
• installation & Commissioning of the Automation system in less than 6 months

THE HEART OF THE SYSTEM: NX-ERA JET

The PLC promotedin this project by Messung was the NX-ERA JET PLC. This high-performance CPU offers the best cost-effective solution combination of input and output modules for large and distributed systems as well as medium to small sized applications. Jet can be also combined with the main products of the series, such as CPUs, backplane racks, communication and fieldbus modules.

Powerful Features

NX-ERA Jet has all the important features of the popular NX-ERA Series. It turns into a selection of input and output modules where requirements such as hot swapping and advanced functionalities such as OTD (One Touch Diag) and EPS (Easy Plug System) are no longer necessary. The result is a group of compact and economical modules capable of providing highly competitive solutions, with no loss of electrical characteristics such as isolation, performance and accuracy.

• NX-ERA Jet has integrated power supply & I/O points, reliable and compact I/O modules
• For more flexibility and agility in the development of applications, NX-ERA Jet counts on WEBSERVER
• Offers high speed counters and PTO for simple motion applications

BENEFITS FOR THE CUSTOMER

• SCADA&HMI systemenables the customer to obtain information leading to better process traceability, and storage of performance data which is essential to correct quality issues.
• Remote IO system on MODBUS TCP communication provides access to sensor-level data in difficult-to-reach areas. This ensures smoother operation of system components while streamlining device replacement and machine maintenance – again saving costs and improving efficiency.
• Total IO Count- 600nos.Since all Input/output signals are connected to a single controller, this avoids expensive multi PLC controller systems.
• Network of 26 nos. of VFDs: Due to networking, only communication cable is required which is much easier to install and less expensive than many cables otherwise required for connecting discrete signals to control the VFDs.
• Auto-Tune PID controllers automatically regulate process parameters such as speed, pressure, temperature, etc., and keep the actual output as close to the target/setpoint output as possible.
• System supplied at affordable price

OUTCOME

The client has reported an increase in productivity and reliability, and decrease in costs. Also, by reducing manpower dependency, the new system has generated a significant reduction in the number of problems relating to product quality and operator safety.

ABOUT MESSUNG

Messung is one of India’s leading Industrial Automation Companies offering cutting-edge, custom-built solutions for Process Automation, Servo & Motion Control Automation and General Purpose Automation. Counted among the top 10 PLC manufacturers, Messung offers a range of world-class Programmable Logic Controllers (PLC), Remote I/O Modules, Servo & Motion Control solutions and Human Machine Interface (HMI) for a gamut of applications across diverse industries.

Messung also offers a wide range of Variable Frequency Drives (VFDs) and Servo/Motion products from Fuji Electric for simple to complex industrial applications.

Messung partners throughout the complete life cycle of your plant, and customises industrial automation & control solutions that meet the highest technical demands for speed, quality, operational reliability, system availability and more.If you’re searching for a PLC automation partner for your industry, consider Messung – PLC automation company with four decades of experience and proven expertise to their name.

For more information about a href=http://www.messungautomation.co.in/productsprogrammable logic controller, call us on +91 20 66492800