Industry
- Advanced Materials Science
Technology Used
- Allen Bradley (by Rockwell Automation) CompactLogix
- Ignition by Inductive Automation
- NeoMatrix’s standard code library for PLCs and Ignition
Project Overview
This advanced materials science company needed to implement a scalable cleaning process in order to scale to accommodate various production demands. The company’s goal was to implement faster cleaning processes and minimize downtime in production.
It also wanted the ability to quickly adjust the cleaning process to different volumes and sizes of production without significant changes in infrastructure or procedure. With the integration of automated systems, the company could ensure consistent and repeatable results.
Challenges
The cleaning process was complex and inefficient given various factors. There are separate machines for different chemicals, and they are stored in different areas of the facility, complicating logistics. The chemicals need to be distributed to a mixing unit before being used for cleaning, adding extra steps to the process. Delivering chemicals to filters requires 100s of valves and pumps, and the system must also manage waste chemicals, adding complexity and potential points of failure.
Solution
Implementing a scalable cleaning process for an advanced materials science company involves addressing both the technical and safety aspects of cleaning operations. It came down to the design and development of equipment modules that would control chemical distribution and mixing, and phase logic to clean the filters.
NeoMatrix leveraged standard code modules and the acquire and release concept in the PLC logic to manage the control of shared resources in the industrial automation systems. This concept ensures that only one process or machine can access a particular resource at a time, preventing conflicts and ensuring safe and efficient operations.
When a process or machine needs to use a shared resource, it sends a request to "acquire" the resource. In this case, the resource is the filter. If the resource is available (i.e., not currently in use by another process), the PLC grants access and the resource is marked as "acquired" or "in use." The process then proceeds with its operation using the resource.
After the process has finished using the resource, it sends a signal to "release" the resource (filter). The PLC then marks the resource as "available" again, allowing other processes to acquire it. This ensures that the resource is free for use by the next requesting process. This systematic approach ensures that the filter is not used by multiple machines simultaneously, preventing operational conflicts and ensuring safety.
The units existed in multiple PLCs. IO modules were used to interface sensors and actuators with the control system. Standard logic ensures consistent and reliable data processing and control across all modules. An alarm system was implemented to alert operators to any communication failures or other critical issues. In this case, the system ensures that the communication between PLCs is intact to maintain safety, especially when dealing with hazardous chemicals.
We used Rockwell Automation’s CompactLogix given its additional safety features to handle potentially dangerous operations.
Results
The company’s implemented scalable cleaning process with standardized components and robust safety measures is inherently more scalable. The company can expand its operations, add new processes, or integrate additional equipment with minimal disruption and complexity. Overall, the company benefits from greater efficiency, faster, cleaner filters, while saving costs on filter replacements.
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