Power control system

Electronic systems

Inspection systems

The technological evolution of the production process and the quality requirements in the market has strongly increased the needs for inline control of final products like nonwovens, plastic covering, transparent and coating materials, abrasives, paper and rubber.

In order to meet these Customers’ requirements Electronic Systems proposes different inline web inspection systems able to control 100% of produced material detecting and showing the quality and defects.

Flexin

The Flexin entry level software assure the following real time performance:

• On-line defects detection

• List of defects images

• Defects reel-map

• Defects counters devided by dimensions and type

• Trends

The system is able to detect and classify the defects according to the parameters that have been established. It is possible to enable/disable the visualization by different typologies of defects and/or their dimensional class. The map of the bobbin can be printed out automatically and the relevant data can be sent to the production management system of the factory

SYSTEM ARCHITECTURE

The system comprises a number of CCD cameras, with an integrated PC and Frame Grabber, one or more lights placed on the line and one operator console for visualization and quality control.

The defects are detected in real time and shown on a map which indicates the relevant class and types. It is also possible to include alarms, displays trends and/or counters.

The FLEXIN’s architecture is designed for Windows, it is very adaptable to any industrial requirement and user friendly.

Flexcord

Flexcord  system is a special scanning device, with a X-ray emitter and a linear sensor. For steel cord – rubber production , it it can to monitor continuously monitor the presence of steel cords inside the rubber production for tires.

The high system resolution allows toenables the measurement of the distance between each one cord and the next one, so it can give giving an immediate alarm in case where such distance exceeds the specification.

The performed real-time measurements made  for each scan over the web are the:  number of detected cords;, the average, minimum and maximum of distance and; and the step of cords.

A special measurement can be performed on the edges to  detectto detect the width of rubber outside the first and last cord. This special measurement can be activated achieved on alternate each scanssion or it can be performed continuously continuouslystopping  the head alternatively over the two edges.

The Flexcord system is tuned to work with minimum xrayx-ray emission., it’s controlledIt is engineered not to exceed 37Kv with a maximum current of 1.25mA, while whereas a typical dental  Xrayx-ray device works from 50 to 70Kv with 2 to 8 mA of current.

Flex Feed

Flexfeed system is a calendar feeding control system working with thermographic IR cameras. It  provides stable and reliable information about the amount of material between calendar cylinders. The different IR emissions between the molded plastic and the cylinders provides a clear image of the amount of feeding, no matter the type or color of material being produced.

It is able to work in direct connection with the feeding system to control the amount of feeding as well as its left-middle- right distribution.


Flexfeed includes some useful  additional features like the temperature distribution on the surface of molded plastic that can help to ensure better handling on the first step of film production. The system backs up  continuously a simple AVI file, with one image every 2 seconds, that provides access  to  all monitored production 24hours a day for one year.

Scaneye

Scaneye is a scanning system with one or more cameras that performs inline a detailed online  online detailed analysis  on of a small portion of of a surface., so iIt can perform dimensional measurements onlineinline, moving across the web, withweb with a resolution close tothatto that of  a microscope in laboratory.

Scaneye hasis composed by one camera with a special optic capababiltysolution to get an enlarged image of the web surface. and a It has a lighting unit with high power LEDs that are configured to better enhance the surface viewaspect. Each measurementd feature is compared with a reference grid to producing e a conformity map of all production.

Limitation: The enlarged image needs a very high camera speed;, for this reason it is may beusually difficult to ausepply it Scaneye in productions with speeds faster than 100m/min.

Typical applications: not uniform non-uniform coatings which is not unkform, check analyzing of grit distribution in abrasive productions, embossing checks and such like similar processes.so on.

FlexOut

FLEXOUT – THE LAST STEP FOR A GlOBAL WEB INSPECTION SOlUTION

Our extensive experience using web inspection with Flexin systems has shown that often the defect detection creates a problem, i.e. What to do with detected defects? Thus a web inspection system, like Flexin, is just the first step of a global web inspection solution. Electronic Systems has produced a complementary system called Flexout to finish the job by creating a real web inspection solution.

The Flexout inspection system can be applied every time  a big roll is produced. The roll can then be cut into slits or rewound where defects need to be removed  post production.

A standard solution is to install a labeler so the defect can be marked directly on the web, but this solution requires an operator that continuously checks when the labels are coming and slows down the slitter in advance to find the label position at the  slower speed.

A similar result can be achieved by looking at the defect map saved by the Flexout web inspection system. Electronic Systems has many years of experience working together with slitter operators during Flexin startups.

The experience of Electronic Systems has been included in the Flexout system to make the defect removal process easier and faster by using a statistical approach and dedicated tools.

The Flexout system will automatically stop the slitter at the defect position. By using statistics from day to day operations, it learns how to find the defect positions in a more accurate, safe, and timely way.
Automation

ELECTRICAL ENGINEERING

Electrical engineering is carried out with CAD systems:

• Spac

• Eplan P8

Documents can be supplied in .PDF, .DXF and .DWG format. They consist of:

• Single-wire electrical diagram

• Functional diagram

• Cable lists

• Parts list

• Equipment layout

• Certificates of conformity

• Test certificates

• User manual

• Data sheet of components

With the purpose of offering a “turn key” solution, our company also supplies the plan of the systems on board the machine and offers a work supervision service on site.

Electronic Systems has been working in the automation industry since the very beginning and offers a complete range of products and services suitable for any issue connected to production processes.

We mainly realize the following process typologies:

• Production plants for plastic materials (calendering lines, Cast film, Blown film, Breathable, Coating, and Biax films)

• Production lines for rubber (calendering lines, extrusion lines, RollerHead, Innerliner, mixers)

• Coating and lamination plants

• Plants for fabric treatment

• Cable production lines

Electric engineering, software development and equipment manufacturing are totally carried out in our company. All the equipment is tested in compliance with current regulations in force. Special attention is given to safety circuits whose components and circuits belong to the safety class declared by the machine producer. (Electronic Systems has already enforced the new ISO 13849-1 standard and is at your disposal for supplying documents about its own “performance level”).

Complete plant

AUTOMATION FOR INDUSTRIAL PLANTS

All process variables can be used for data collection and tracking systems. Electronic Systems also provides a teleservice system

and maintenance staff training courses.

SOFTWARE

Electronic Systems uses control systems based on PLCs produced by world leading manufacturers among whom:

• Siemens

• Rockwell (of whom we are “Recognized Systems Integrator”)

• General Electric

• Schneider

• Omron

Signal shift and acquisition use the most widespread field buses such as:

• Profibus

• Profinet

• ControlNet

• DeviceNet

• Modbus

• Ethernet/IP

The machine user interface is built using local operator panels and SCADA systems based on market leading packages:

• Siemens WinCC

• Intouch

• RSView 32

• GE Cimplicity

Rework

SYSTEM DESCRIPTION – POSSIBlE APPLICATIONS

Production line, commonly denominated as “Rework Line” design to process to rubber sheet shape after filter it (filter is a process option), rework tire components like treads and sidewalls, by means of combine control utilization of mills, straining by gear pump and

palletizer equipment (batch off).

• Sheeting process: rework tire components are feed by means of a conveyor into a cracker mill and after that automatically transported to a homogenizing mill, and consequently to a feeding mill, finalizing the process in a sheeter mill. After that is cool down and palletizer in a batch off equipment.

• Filter process (1st option): same as sheeting process, but before material be transferred to the sheeter mill is filtered by means of a gear pump and a strainer head.

• Filter process (2nd option): Case material is already in a sheet format and is necessary only to filter. Process is starting by means of a batch feeder conveyor directly in the homogenizing mill. After that same process as steps before.

PROJECT MANAGEMENT CAPABILITIES

• Layout can be work out according the available space using 3D design tools

• Automation & control using possible different solutions as Siemens or Rockwell

• Turnkey installation possibility or supervision base

ADVANTAGES OF A REWORK LINE

• Prepared to strain final batch compound with a max output of  2,5 t/h

• Prevent strange material coming from the “workoff” to appear in compounds, green and cured tires

• Sheet the Sidewall and Innerliner work-off, increasing the mixing capacity by not using that time in a mixer equipment

• Recover for normal use not approved compounds with strange material or cured rubber (scorch)

• Space restrictions in the mixing room. Sheeting process of “workoff” compounds (tire treads and sidewalls) creates conditions to storage in automatic • • warehouse (high bay storage) or standard shelving

• Sidewall output increasing by straining critical compounds offline

• For plants using cap strip process machines, increasing of the output by filtering the material in advance and offline

• Clean batches coming from mixing line with scorch, reducing scrap

• Low maintenance equipment, due the “friendly” maintenance solutions developed

• Line easy to operate.

Mills

Our mills stand out due to their strong steel casting construction, compliance with the current Eu standards, and their fully integrated capability of automation, in the several different market platforms, as Siemens and Rockwell.

Depending on the final application we can customize the mill to you own application, below some im-

portant features:

• Range of specifications: Ø 360mm – Ø 810 mm and roll width from 40” to 84”

• Construction of mill rolls: drilled roll, bored roll, grooved roll, made of special chilled cast iron with long service life

• Methods of adjusting roll nip: manually, electrically, hydraulically

• Drives: AC, DC, hydraulic

• Prepared to be tempeture controlled in the roll, by TCU (temperature control units)

• Compliance with the current EU standards

• Possible to be equipped with additional customer requests as: cutting devices, stock blender, different drive options, ie, individual roll speed or constan.

Complete revamping

The decision to revamp equipments has as background the following reasons and arguments:

• Spare parts for installed equipment have become obsolete or very expensive

• Equipment isn’t complain with safety and CE normative

• Maintenance becomes expensive and production down time increases

• Production time cannot meet market demands or new product recipes are too complex for old equipment

• When companies are relocating equipment from other manufacturing locations requiring installation with a current system; revamping is a solution.

Renovating and reconstructing from mechanical and automation point of view equipment from the rubber and plastic industry, with special focus in:

• Extruder Lines

• Calender Line

• Innerliner lines

• Rework Lines

• Mills

• Other special applications under request.

Turn key plant

Turnkey experienced capabilities areas in the rubber and plastic field:

• Project survey or OEM description interpretation

• Layout design (supported by 3D tools)

• Project Gantt definition

• Engineering/Equipment selection

• Software design (Siemens, Rockwell, Beckoff platforms or others under request)

• HMI/SCADA visualization system with or without DB integration

• On site installation (mechanical and electrical)

• Project commissioning

• Training

• CE declaration.

ELECTRONIC SYSTEMS is experienced in assisting companies with turnkey projects, from OEM projects to revamping projects we can work the project from the survey phase to the last phase, ie, equipment training and machine handover.

We can take the full responsibility of the project, following the client specification using our internal solutions and partners or we are also prepared to work with client customized partners.