Integrating programmable logic controllers (PLC) into process weighing systems in assembly lines can boost productivity and improve output quality. First invented in 1969, PLCs are responsible for continuously monitoring inputs and outputs into the entire operation to make calculated decisions that adjust and fine-tune different components of process weighing systems. If you're still running on old technology, it's time to upgrade your production line. Here are 3 essential commands and features that will make a world of a difference.
Accuracy and Precision in Blending for Improved Efficiency
The batch time required by process weighing systems significantly impacts cost and productivity. If your process weighing systems are responsible for blending any ingredients or solutions together, PLCs will significantly reduce your batch time, and easily adapt to changes in the recipe. PLCs can monitor and control multiple weighing systems at a time and control both feed and cutoff rate in an accurate and efficient manner in order to reduce errors. An algorithm pertaining to the weight requirements is directly downloaded to the PLC.
This automatic process helps to reduce the time that you would otherwise need to calculate minor changes. In addition, the precision of the PLC is crucial in quality control.
Improve Overall Efficiency through Flow Control
Fluid viscosity and flow through the hydraulic systems and any piping will influence energy usage and waste. Viscosity of fluid within hydraulic systems should ideally be at 25 to 36 centistokes; however, enforcing fluid control can be difficult. Traditionally, assembly lines require various measurement devices and manual alterations in the physical systems to achieve the ideal flow rate. PLCs monitor pressure and flow of all fluid, and utilize proportional flow-control valves to ensure that all elements within the system are proportionate to one another.
In short, if the temperature within the process weighing systems change, the flow rate of substrates and solutions that are being blended and measured will alter and be affected, thus resulting in inaccuracies and inefficiencies. To make it simple, minor fluctuations can easily throw an entire system off, and mess up the quality of the output. By integrating PLCs and proportional flow-control valves into the assembly systems, the flow path will automatically adjust, along with the internal pressure, to ensure that the weight of all substrates and solutions that are processed is still proportional to the original requirements and ignore plant and processing noise.
Analyze System Processes with Improved Communication Methods
PLCs are not only able to help regulate system production and ensure consistency in the quality of the outputs, but will also help you make more informed decisions. PLCs convey information through an I/O module that can be communicated across various platforms. In short, you can get a good idea of how various areas of your assembly lines are performing, and whether there are any issues, such as inefficiencies, that may need to be addressed immediately.
You can easily create reports and various analyses of different variables pertaining to the performance of the process weighing systems just by simply integrating a PLC controller from a firm like Flodyne Incorporated. This will help you save a lot of time and sleepless nights that would have otherwise been spent pouring over numbers.
Conclusion
With high standards for assembly line outputs nowadays, having the right technology will help your company move in the right direction and stand out from competitors. As your plant expands, the ability for your process weighing systems to monitor fluctuations and changes in both inputs and outputs will reduce overall expenses and boost productivity. There are different commands, software programs and accessories that can be installed and integrated along with PLCs to further cater to the demands of your process weighing systems.
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