Pneumatic Energy Saving & Efficiency System

Posted by Chuck Harrell on Jan 21, 2016 11:00:00 AM

Industrial forging is a manufacturing process involving the shaping of metal using localized compressed forces.  The blows are delivered with a hammer (often a power hammer) or a die.  In a hot forge, the metal is heated and used to manufacture parts weighing less than a kilogram to hundreds of metric tons.  Industrial forge air compressors consume about 60% of the total electricity in the factory.  By introducing a pneumatic energy saving system, an awful lot of this electricity can be reduced.  Once installed, this new system needs to be properly maintained to ensure that it reduces production costs.

Requirements

It was essential that the efficiency of the air compressor would be monitored at all times for air flow and electricity consumption and control the demand and supply of compressed air through analysis of producing pattern to minimize the waste of energy.  These requirements would be met by monitoring the flow meter, watt-hour meter, pressure sensor, thermos hygrometer, LET modem through a database.

Implementation

Advantech used two ACP-4300 servers with Intel Quad Core Processors and the monitors had WebAccess installed on them.

Going beyond SCADA, WebAccess is a HTML5 Business Intelligent Dashboard which can be opened from anywhere on any HTML5 compatible browser.  The Business Intelligent Dashborad analyses data and helps managers make decisions as to what to do and WebAccess also provides developers with the tools to design their own widgets and applications.   Included is a set of Excel templates or users can build their own report templates. Through HTML5, a limitless number of users with varying access levels are able to read information and make changes from wherever they are using either the Internet or the Intranet.   To monitor this information, not only can it be viewed remotely but also on the FPM-7211W.

To communicate with the data acquisition devices, the ACP-4300 was connected via Ethernet to an EKI-2525 wide temperature five port Unmanaged Industrial Ethernet Switch and to connect to the flow meters via a data acquisition drive, the system integrator used an EKI-6311GN wireless access point.

The EKI-2525 supports a fast Ethernet solution.  The power is a 12 - 48 Vdc redundant input design and is secured with a double protection mechanism, the Power Polarity Reverse Protect and an Overload Current Resetable Fuse.   The former tolerates reverse power wiring while the later secures the system from overload currents.  As the power supply turns normal, the EKI-2525 will automatically get back to work.  Each port of the EKI--2525 has two LEDs to show the link status transmission speed and collision status.  It will also provide a relay output for an event alarm.  In the event of a power failure, the built-in LED will activate the alarm to notify administrators.  Engineers can simply verify the hardware status by checking the LED and troubleshoot with ease and quickly.   The EKI-2525 comes with compact metal housing that rates IP30 to help against dusty environments.

The EKI-6311GN is a feature rich wireless AP/CPE which provides a reliable wireless connectivity for industrial environments.  The PoE injector enhances flexibility in deployment even where the DC power supply is hard to fulfill.  As an 802.11n compliant device, the EKI-6311GN provides three times higher data rates than legacy 802.11g devices.  With the support of STP, WMM, and IGMP snooping protocols, the EKI-6311GN effectively improves the reliability of wireless connectivity, especially in an app.

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Topics: Automation Software, Industrial Communication, Human Machine Interface, Remote I/O

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