Case Study

Extruder Line Temp Control:

Problem faced:

The customer operates a plastic extrusion production line that has inefficiencies due to outdated components in their extruder drive zone. The motor contact starters in use have reduced power efficiency, potentially shortening motor life due to the abrupt starts and stops. Also, the existing human-machine interface (HMI) only monitors hopper levels, limiting the diagnostic capabilities for maintenance personnel and operators. This situation hampers proactive troubleshooting efforts, potentially leading to production halts and quality issues. Furthermore, the absence of remote junction boxes complicates future motor replacements or testing, posing significant operational disruption and downtime.

AFI Systems solution:

AFI Systems upgraded 3 production lines over the past two years. The plan was to replace the motor contact starters with more power-efficient AC drives, which would also extend motor life by smoothing the start and stop cycles. Control panel installations designed and built at AFI Systems, along with touchscreens, would provide operators and maintenance personnel with an overview of the start and stop states of each fan, the temperature of each zone, and hopper levels. This enriched diagnostic capability could help prevent quality issues through early troubleshooting.

Additionally, the upgrade would migrate the hopper level monitoring to the new HMI, based on customer preference. Further, the upgrade allows for additional functionality to be added at a later date. The remote junction boxes would also allow easy connection points for future motor replacements and/or testing. To ensure seamless integration, the system and drives would be controlled by the existing PLC. A manual start and stop screen was also provided for troubleshooting and testing.

The new system comprised numerous components, including enclosures and sub-panels with stands, ethernet switches, 18 PowerFlex 525 Drives, touch screens, and extensive wiring and programming.

Results:

The upgrades system provided improvements in power efficiency and motor lifespan, resulting in an expected decrease in maintenance costs and unplanned downtimes. The new HMIs facilitate better monitoring of various operational aspects, including fan states, zone temperature, and hopper levels. This resulted in a more proactive approach to identifying potential issues, minimizing the risk of quality issues and production halts.

The easy-to-access junction boxes simplified the process of future motor replacements and testing. The upgrade also led to a considerable reduction in operational disruption and downtime, further enhancing productivity and operational efficiency. Finally, the enhanced diagnostics also contributed to reducing waste and enhancing the quality of their products, thereby enhancing their market competitiveness.

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