CD Automation has been committed for over thirty years to helping engineers and system designers reduce plant complexity and costs by integrating temperature control systems based on SSRs for intelligent production.
A particularly exciting area for the company, based in Legnano, is the plastics extrusion industry, for which the focus is on optimising heating performance.
The stakes
Plastics extrusion is a special plastic deformation procedure, aimed at the production of ‘extruded’ parts with a constant cross-section, such as tubes, bars, profiles, sheets, plastic films or, more simply, granules composed of different materials, which will then be used for other processes.
Specifically, during extrusion, plastics (in the form of small granules) are heated to specific temperatures and melted together. They are then processed to a specific shape and finally undergo a cooling and consolidation process.
From this brief explanation, it is easy to see how accurate temperature and power control is crucial to the proper functioning of the system.
Overcoming obstacles with CD Automation
When addressing the topic of performance improvement for plastics machines, with a focus on the units involved in heating processes, two specific areas must be considered: the quality of the finished product and downtime. Both have a significant impact on utilisation and maintenance costs, which companies cannot afford to ignore.
So how do you increase production, reduce costs and avoid downtime risks? CD Automation’s in-depth knowledge of plastics machine systems supports production managers in resource-saving design and plant optimisation.
It is therefore essential for companies involved in plastics extrusion to take into consideration the five tips, dispensed by CD Automation, in order to maximise machine performance.
1. Controlling power and temperature with state-of-the-art systems
Investing in the latest generation of electronic devices for controlling loads is the winning choice. A higher initial cost, compared to electromechanical contactors, corresponds to a longer life span: electronic devices can in fact achieve up to 10 years of life, thus reducing downtime, due to possible replacements, and utilisation costs, which are little considered by companies when purchasing.
CD Automation è specializzata nella produzione di apparecchiature avanzate, a elevato contenuto tecnologico, studiate appositamente per l’estrusione delle materie plastiche.
2. Correct dimensioning of power control devices
When dimensioning the power control device, the line voltage, heating element and temperature rating inside the control cabinet must be taken into consideration. If proper care is not taken, the risk is that the device is under-dimensioned and thus operates at or even beyond its limits, resulting in a reduction of its service life.
For this reason, CD Automation undertakes to size the power controller according to the load, adding a 15% safety margin to cover possible fluctuations in supply voltage and temperatures.
A care for the customer, the processes and equipment involved in plastics extrusion, which results in units that last more than ten years.
3. Consider the derating curve of components according to the temperature at which they can be used in warmer months
Too often, companies ignore a variant that is as insidious as it is silent: the change in ambient temperature. In reality, every 10 degrees C. rise over ambient temperature cuts electronic life in half.
CD Automation invites you to periodically measure the temperature inside the cabinet and manufactures power controllers sized to operate up to 40°C in continuous duty. Should the measurement exceed this figure, a team of experts is ready to correctly size the air conditioning or cooling of the control cabinet.
4. Pay attention to how the units are fastened and connected within the control panel
Electrical connections need to be mechanically tight to ensure that the resistance across that connection is as low as possible. When a connection becomes loose or corroded, it develops resistance, which, when current flows, dissipates power in the form of heat and can even cause the connection itself and the surrounding wires to melt. Faulty wiring can also cause your electricity bill to increase. Faulty wiring can also cause your electricity bill to increase.
5. Carefully consider the effects of mains voltage fluctuations
Poor quality or fluctuating power supply can often cause power surges, spikes and voltage fluctuations that can result in component damage. The causes, as well as the consequences, can be manifold. It is therefore essential to ‘arm’ yourself with power units equipped with voltage feedback to quickly compensate for voltage increases and provide the power required for the thermal process.
This avoids wasting energy and exceeding the temperature of the plastics, resulting in a result that meets production specifications.
A ‘family’ serving the plastics industry
CD Automation does not limit itself to suggestions, but provides an entire family of multi-channel units pto meet every need in plastics extrusion.
Leading the way in this respect is the REVO Series, designed to improve the heating process and save time, costs and resources by up to 70% compared to a solution consisting of individual components. In fact, the modular system allows the integration of all components and control functions for electric heating.
REVO PN is equipped with intelligent diagnostic functions that immediately detect and locate errors in the load circuit, supported by extensive system diagnostics.
In addition, libraries and examples already available for the TIA Portal environment make the heating process easily integrated into the automation system, while an integrated load management allows the load to be evenly distributed over the network, as far as the specified setpoint values allow.
Keyword: Power Qualityy
The main objective of CD Automation products is power quality, which is achieved by reducing disturbances on the power supply line, heating of electrical cables and energy losses. Such disturbances are generally caused by flickering, due to the insertion of unsynchronised loads, which has a negative impact on power quality. Thanks to the REVO POWER NETWORK control system and Dynamic Burst Firing technology for optimising electrical loads, CD Automation ensures Power Factor values very close to 1 and minimises energy cost penalties and disturbances fed into the grid.
REVO PN: intelligent management of electrical loads
Main character of CD Automation’s commitment to Power Quality, in the plastics industry but not only, is the REVO PN multi-channel power unit, designed to handle applications with many power zones. Thanks to the power distribution algorithm, it is possible to balance and limit the peak current demand, thus maintaining a high quality of the absorbed current, limiting losses and consumption.
REVO PN units meet modern needs for connectivity, data acquisition, monitoring and diagnostics of industrial plants via the most popular fieldbuses and are the ideal complement to temperature control functions.
Do you want to find out how to make your plastics plant heating system more efficient and competitive? Contact us and book a free consultation session with one of our experts. You will receive strategic proposals to enhance and increase the lifespan of your heating systems and minimise downtimes.
