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St. Louis, MO, USA (June 23, 2003) - Watlow's PPC-2000 offers a new class of high performance controller that provides all types of extrusion processors with easy-to-setup multi-loop process and programmable logic control in one complete package. The PPC-2000 allows companies to accurately quantify the results of process changes, enabling them to establish a consistent processing window while minimizing scrap and downtime. It also offers a very user-friendly alternative to the use of individual controllers and PLC units from different vendors and tangible benefits can be felt from the plant floor to upper management.
Because Watlow's PPC-2000 is a modular, flexible package, extrusion houses can now speed time to market with the quick, customisable options available. The PPC-2000 provides faster start up due to easy PID set up with "fill-in-the-blank" and pop-down menus. This results in greater productivity levels and reduced process downtime. In addition, custom, intuitive screens with colour pictograms of the die, extruder, barrel and all control zones, make the system very easy to use and understand. Flexible system security for different types of users is available and a backup system is provided in case of an on-floor touch screen failure. With the touch-screen option, users can easily switch from loop-to-loop to monitor and troubleshoot the extrusion process.
The implementation of ANAWIN® HMI (Human Machine Interface) software eases channel parameter setup and monitoring as it is a simple, menu-driven, full-featured and customisable package that allows all the control loops to be viewed and edited from scrollable tables. Because no programming is necessary, productivity is immediate. Additionally, customers can link all their equipment to a central point. This enables users to control the process from the shop floor or from within a central office area.
Through the use of ANAWIN, the PPC-2000 offers processors complete production run documentation including features such as data communication, process monitoring and recipe storage. These features help the processor ensure repeatability and ease of changeover. Other features and benefits include:
- auto tune software for fast start-up, rapid response to set point changes, monitoring and optimising material usage, reducing power costs, extending motor life and cooling control of water, air and oil
screw speed control for consistent operation
pressure monitoring capabilities
With the PPC-2000, a single controller can be customized to fit the application and can precisely control up to 48 temperature zones and process loops. Because the PPC-2000 is modularised, it can grow with the customers system to allow various analog and digital I/O modules and control loops to be centralized into one compact unit and programmed as an integrated system. The PPC-2000 supports 64 analog inputs and hundreds of digital I/O modules allowing users to select from a wider variety of field I/O devices to match specific application needs. Optional touch screen displays and LCD interfaces are available for easy viewing or editing of parameters on the shop floor.
The PPC-2000 can add custom functions by using its state of the art LOGICPRO graphical logic programming software utility. It is used to develop and download logic programs that run alongside and interact with the closed-loop, PID control program in the PPC-2000. LOGICPRO enables the processor to easily create, test and install a program in the PPC-2000 using drag and drop programming and quickly debug their programs more quickly prior to completing the integration of the PPC-2000 with the rest of the system.
Economic Benefits
Watlow's PPC-2000 offers many economic advantages. Because it combines closed-loop and programmable control, the need for two separate controllers is eliminated. The PPC-2000's pre-configured, closed-loop control eliminates labor-intensive ladder logic PID programming as well. The PPC-2000 also lowers costs by measuring up to 32 different types of thermocouple and analog signals with one module. Additionally, the high-density, flexible I/O efficiently utilizes panel space. Customers can change a digital output to an input and vice versa without adding hardware or rewiring the system. With the PPC-2000's auto-tuning software built in, the need to purchase special auto-tuning software is eliminated. And finally, a reduction in maintenance costs can be achieved by prolonging the heater life with the DZC (burst-fire) heater control outputs.
Benefits From the Shop Floor to Management
Because Watlow's PPC-2000 is easy to learn and use, saves time, provides easy maintenance and troubleshooting and results in less down-time, benefits are realized throughout the customer's organization. Machine operators are able to provide input into process views, which leads to a sense of process ownership. Less time is needed for training and a better overall understanding of the extrusion process results.
Because remote screens enable managers and supervisors to monitor the line and collect and view historical data, they can identify trends and make adjustments. They can then alter processing parameters from their offices and track changes. Manufacturing supervisors see a higher process yield from uninterrupted cycles and an enhancement to overall worker efficiency and satisfaction.
Management will see higher profits due to the increased efficiency, higher process yields, reduced downtime and minimal training requirements. Additionally, they can pinpoint material costs and optimizer resin usage for each production run because the PPC-2000 can monitor raw material usage, percent regrind, and/or additives to set the colour mix using load cells. The PPC-2000's power management feature can also reduce power costs.
The combined savings that can be realized, the robustness, ease of use and expandability of the PPC-2000 all make production more efficient and cost effective. Employees throughout the facility can realize these benefits, empowering them to perform their jobs more easily and readily.
About Watlow
Since the company's founding in 1922, Watlow has brought its thermal expertise to numerous applications, including semiconductor, plastics processing, packaging, foodservice equipment, life sciences, aerospace and others. Headquartered in St. Louis, Missouri, USA, Watlow is the largest custom designer and manufacturer of industrial heaters, sensors, controllers and software with offices and manufacturing facilities around the world.
For additional information or the name of the nearest Watlow representative:
Watlow
Phone: +44 (115) 964 0777
Fax: +44 (115) 964 0071
Internet: www.watlow.co.uk
E-mail: info@watlow.com.sg
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