ImPerio gcs Process automation system for the galvanic Plating of wires and bands
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The Software for Highest Quality and economic efficiency IMPERIO GCS Process automation system for the galvanic plating of wires and bands
IMPERIO GCS Process Automation System for the galvanic plating of wires and bands in continuous pass plants IMPERIO IMPERIO the process management software by CPA has been developed to control, supervise and administer galvanic coating processes in parallel continuous pass plants, e.g. for brass plating in steel cord production. This process control system is fully configurable and parameterizable and, as such, can be used for numerous processes. Among other functions, IMPERIO GCS is able to monitor, visualize, automate and optimize CPA’s galvanic plating units CELLRAC and GALVOMODUL. The advantages of CPA’s galvanic coating units, combined with IMPERIO’s efficient control technology, lead to improved product quality, whilst reducing the overall process costs and increasing operation management safety: Greater precision and constant coating processes: • less scrap • reduced energy costs • reduced electrolyte consumption • minimized water consumption • less personnel involvement IMPERIO GCS is a sector-specific system geared towards the monitoring and control of the entire galvanic production process of continuous pass plants, including related functions such as energy supply, media supply or waste water disposal. As a comprehensive solution to customers´ requirements, IMPERIO GCS is structured in terms of functions and distributed to the relevant computer systems within the individual sections. It is on these computers that the system is operated on site. Thanks to configuration, parameterization and continuous programming, IMPERIO GCS can be fully adapted to your process
01 02 03 04 05
Payoff AEOX GCS AEOX Takeup
IMPERIO GCS
Process
IMPERIO WWTP Energy Supply ABACS LAB
11 10 09 08 07 06
INDEX: 01. Payoff 02. Patenting 03. Plating 04. Diffusion 05. Take-Up 06. Laboratory 07. ABACS 08. DEMIN Water Supply 09. Energy Supply 10. Wastewater Treatment 11. Operator Terminal
IMPERIO GCS
IMPERIO GCS SOFTWARE MODULES Manage your entire production
Always up-to-date with IMPERIO GCS with IMPERIO GCS
SUPERVISION. The control room module MES. The manufacturing execution module
The supervision computer has been designed to monitor the entire databases and servers are used. If no connection to the ERP system The IMPERIO GCS MES component closes the information chain from the order, e.g. article data or product specifications such as layer
plant from the central control room. It gathers information from the is possible or desired, the customers‘ orders and recipes are directly between the detailed planning or the ERP system and the production weight or coating thickness, in order to avoid setting errors resulting
various applications and computers in order to provide the operator in dispatched to IMPERIO GCS and, if needed, scheduled using the in- process. The MES provides order-relevant data at the process level in reject products.
the control center with the best possible overview of the process. The tegrated detailed planning module, SCHED. Once the data has been and to the machine. It automatically uses specified data (recipes)
man-machine interface (MMI) can be tailored to the specific needs planned, it is transferred to the MES, the executing module, so that it
of the plant in question and designed ergonomically by means of can launch orders and set up process parameters.
dynamic plant graphics and graphic automation objects (CPA Power During operation and upon order completion, they are calculated,
Objects). IMPERIO GCS starts working once the order for production reports are produced and statistic process controls (SPC) are genera-
has been placed, by extracting the order from the production plan- ted based on laboratory and online process data.
ning and control module of the ERP system. For production orders
and recipes, universally configurable and parameterizable interfaces,
Analyze your past and future process development
with IMPERIO GCS
SPC. The statistic module
In order to document and improve the process quality, the IMPERIO line process data, test data from material tests such as wire diameter,
GCS process data collection is followed by a statistic analysis. The strength or results of chemical analyses or consumption rates can be
statistic module collects all process-relevant data in real time and pre- analyzed. All the results can be assigned as quality documentation of
sents them e.g. in the form of up-to-date control cards. This enables either the orders or the batches.
the operator to react quickly to quality problems. In addition to the on-
Schedule your
production dates at
shop floor level
with IMPERIO GCS
SCHED. The planning module
In order to increase planning efficiency and improve the processing
of production orders, data from a previous detailed planning control
center can be transferred to IMPERIO GCS. During this process,
specified data such as dates, times and quantities are extracted and
compared to real-time feedback pertaining to work progress, produc-
tion quantities and downtime, so that the planning can be promptly
corrected if necessary. This allows problems to be dealt with early so
as to avoid delivery problems.
IMPERIO GCS
Precise documenting of your processes The integration of your entire process starts
using IMPERIO GCS with IMPERIO GCS
REPORT. The documentation module PAYOFF. The payoff module
IMPERIO GCS offers different standardized reports enabling pro- current abnormalities, split-up processes etc. pertaining to each pla- The PLC of every single payoff unit is connected to the payoff station change or failures such as wire ruptures or exceeded change times.
duction performance to be documented. These include an overview ting cell are recorded. All reports can be optionally generated to give via a bus system. The payoff module monitors all payoff processes Here, operation mode, braking force (if operated manually), control
of the current plant utilization with articles and their specifications, details regarding shift, day, month, quarter, year or other customer and displays their status, e.g. dancer position, braking power, spool parameters etc. can be adjusted.
as well as produced quantities expressed as the number of spools, defined periods.
length and weight. Moreover, the number of incidents, voltage and
Increase the operational availability of your Aeox Energy managment
plant and support your maintenance personnel The heat treatment module
using IMPERIO GCS
MAINT. The maintenance module CPA has risen to the challenges of the future - with AEOX Industrial the energy-efficient heat treatment system and the CPA plating plants,
Furnaces it has developed a revolutionary, cutting-edge heat treat- IMPERIO GCS achieves sensational optimization levels with regards
Via the process control system, the IMPERIO GCS maintenance maintenance can be ordered or personnel can be scheduled in time.
ment technology including heat recuperation for steel wire production. to energy, costs and quality. What’s more, IMPERIO GCS can extract
module collects the operating hours and the operating cycles of However, periodical maintenance work can also be administered. The
These energy-efficient and combustion-optimized furnaces are fully and monitor the process data from external systems, provided that
the unit to be maintained and supplies the operating personnel with completion of maintenance work is confirmed within the system and
adapted to IMPERIO GCS’s general concept of integrally managing they are equipped with the necessary standard interfaces.
instructions in the form of daily printed maintenance lists. When the work that has been carried out is documented in the maintenance
energy and minimizing plant operating costs. Combined with AEOX,
doing so, the module creates advance warnings, based on critical logbook.
levels that can be chosen as desired, so that materials necessary for
IMPERIO GCS
Manage your plant with IMPERIO GCS
PRO. The plating process management module
• The GCS PRO module controls the following process sections: Filter systems are used to clean the electrolytes and the pickling
- Quenching after heat treatment media. These need to be maintained and back-flushed depending on
- Pickling their contamination.
- Polishing, if necessary
- Flushing and drying The bath temperature and the temperature of the pickling and
- Galvanic coating cleaning media are heated or cooled by means of partly cascaded
- After-treatment heat exchangers. GCS PRO supervises and monitors the necessary
process elements in the framework of an integral energy optimization
Every process section has recirculation, temperature regulation, system.
filter, dosing and top-up systems. Moreover, the entire pickling
and galvanic power supply has to be controlled, monitored and Due to evaporation and the continuous drag-out of pickling and
coordinated in order to ensure a constant current density. coating media, a regular dosing of water and mother solution using
an automatic top-up program is necessary. With regard to pickling, an
Driven contact rolls are synchronized with the wire speed that is automatic ground and floating sludge exhaustion is also carried out,
determined by the take-up units. In case of differing wire speed, the with the removed volume being fed into the receiver tank.
speed of the predominant number of wires with the same speed is
deemed to be the relevant speed.
• In general, all fluid tanks feature redundant pump systems with all
necessary safety requirements:
- Monitoring of levels, temperature and pumps
- Periodical pump change
- Automatic change in case of failure
- Dry running protection
IMPERIO GCS Put your quality on solid ground with IMPERIO GCS MELPICK. The pickling unit module Power control relating to the current number of wires and including voltage monitoring, failure documentation and temperature- dependent adaptation is carried out with regard to a high-quality pickling process in a multi-level electrolyte pickling plant. The IMPERIO GCS Manager Imperio Gcs Manager. You decide the recipe of your desired final product The GCS Manager is responsible for precise coating processes. Given that it is easy to use and that adjustments can be made quickly in the form of article-based recipes, it efficiently prevents operating errors and reject products whilst automatically calculating the necessary currents and current densities based on article specifications such as coating thickness, minimum layer weight or alloy composition. Cell failure compensation Monitoring and automatic adaption If adequate coating cannot be guaranteed due to physical circum- In order to run the plant with the lowest possible level of personnel stances such as cell short circuits, a lack of anode material, shortfalls resources, on-site monitoring of the plating cells is supported by in ion concentration or equipment failure, this will be compensated indicator lamps or large displays. Based on the plating analysis data by automatically splitting up the current to neighboring cells, or, if entered in the laboratory station or via online measuring and testing necessary, by reducing take-up speed. In the event of wire break, the devices, an automatic adaption of the article parameters can be effected power supply modules are turned off for safety reasons and induced further to statistic analysis. will be turned back on automatically after threading in order to ensure that they become productive again as soon as possible.
IMPERIO GCS
All’s well that ends well Caring for the
with IMPERIO GCS environment
TAKEUP. The take-up module
with IMPERIO GCS
Well-functioning, fully integrated take-up units are a prerequisite for WWTP. The waste water treatment module
smooth galvanic coating processes.
The PLC of every take-up unit is connected to the take-up station via
a bus system. The take-up module monitors all take-ups and pre- An already existing waste water treatment unit can also be connec-
sents their status, such as speed, spool filling degree, spool change ted and administered using IMPERIO GCS. The purification and
or disruptions such as wire fracture, excess temperature, FU or gear neutralization of waste water can be carried out either continuously
failure. It is also here that the speed for start and production, starting or in batches (batch process), which are controlled, monitored and
ramp, wire tension, meter pre-selection, etc. can be chosen. documented by the system. However, manual control measurements
that might be necessary can also be included. Usually, the generated
records have to be handed over to the respective authority as evi-
dence of correct operation management. IMPERIO GCS WWTP fulfils
this task to perfection.
Fully automatic bath
Clean is often preparation and bath
not clean enough maintenance based
water regeneration as an integral part on a recipe
of your galvanic coating process - with IMPERIO GCS
controlled and monitored by IMPERIO GCS PREP. The preparation module
DWTP. The water processing module
The baths and chemicals needed for the coating process are often
To process tap water, softening or DEMIN water treatment units with prepared, stored and regenerated centrally. The preparation of baths
ion changers or reverse osmosis are mainly used and are often back- is carried out using the IMPERIO GCS PREP recipe control. The infor-
flushed, cleaned, regenerated and dosed in batch mode operation. mation that exhausted fluids need to be topped up is sent automati-
Similarly, recirculation systems are used for water economization, cally via the linked computers.
which recycle the flushing water and feed it back into the process
system. All water treatment processes for cost-effective supply of the
necessary process fluids are monitored, controlled and supervised by
IMPERIO GCS.
Constant pickling quality
with IMPERIO GCS
AREG. Das Regeneration module
The cleaning and regeneration of pickling media (e.g. sulfuric acid
retardation system or phosphoric acid regeneration) and other chemi-
cals is performed fully automatically by IMPERIO GCS and is mostly
controlled, supervised and documented in discontinuous batch mode
operation.
IMPERIO GCS Efficiency and operating safety of your supply systems systems with IMPERIO GCS UTILITIES. The supply module IMPERIO GCS UTILITIES supports you with the supply and ma- nagement of energy, media and other infrastructure with regards to the necessary quantities and constancy. This module is based on a continuous monitoring of all agents and media. The temperature of heating and cooling agents, the pressure of air compressors, fresh air and exhaust fans, as well as the quantities and temperatures of clean water are continuously documented. In the case of deviations, the personnel is informed and reserve systems are activated. If production-critical media fail, the production is even stopped automa- tically. To enable product calculation, consumption documentation is prepared, whilst energy quantities are reported and attributed to the different batches. Energy recovery plants are also integrated in order to allow for energy-optimized operation management. Automatic bath analysis and bath maintenance ABACS. The Automatic Bath Analysis and Control System This online analysis and dosing system has been developed by CPA to compactly connect your laboratory directly with the production pro- cess. The fully automatic bath analysis, control and dosing ensures a constant electrolyte composition and, as an IMPERIO GCS module, is key to ensure a high product quality. Document and analyze your laboratory samples with IMPERIO GCS LAB. The laboratory analysis module If online process data which has been collected by IMPERIO GCS is complemented by offline measurement data, then this data should be fed into the system and consequently made available for the automa- tic adaptation of the plant. The laboratory module enables the measured sample values to be attributed to the batches. If enough samples are available, the article parameters are subsequently adapted based on statistic procedures (control cards) to further improve quality. The results can also be used for product documentation in the form of test certificates for the customer.
Technologies for Excellence
As research+development oriented, international company According to our core values Competence - Perfection - Ambition
group, CPA provides advanced, high-performance technologies and our corporate principle TECHNOLOGIES FOR EXCELLENCE
for a wide application range in the fields of wire production, we continuously strive for the best. For the success of our customers.
automation, electrical and environmental engineering.
CPA product lines
• Industrial Furnaces • Wire-Guiding Equipment
- AEOX ECC: Recirculation Convection Furnace - ROLLOC
- AEOX STS: Microstructure Transformation System
- AEOX EXC: Cross-flow Convection Furnace • Wet Drawing Machines
- LINNOX
• Continuous Plating Plants – Single Cell Control,
Group or Segmented Control • Stranding Machines
- CELLRAC - TAUROP
- GALVOMODUL
• Process Management System
• Pickling Plants - Imperio - PMS
- MELPICK
• Manufacturing Execution System
• Electropolishing Plants - Imperio – MES
- MELPOS
• Plating Control System
• Fully Automatic Bath Analysis and Control System - Imperio – GCS
- ABACS
• Programmable Logic Controller (PLC)
• Dryer - Micromatic
- STRYCOC - Comatic
• Double Capstan - Take-up and Payoff Units • Industry Terminals
- ROTACC - H - XILOC
- ROTACC - V
• Sensors, Transmitters and Actuators
• Tangential Take-up and Payoff Units - PACOS
- ROXSTA
• Fully Automatic and Manual Flyer Payoffs
- FALSTA
Technologies for excellence Changes reserved with regard to
technical development.
CPA Wire Technologies GmbH, Lagergasse 322, 8055 Graz, Austria, phone: +43 (0) 316 46 70 0
e-mail: wiretec@cpa.at, www.cpa.atYou can also read
