Digitalization of Wet Grinding Process for Maximum Efficiency

 

Abstract

Manufacturers are investing significant time in researching improved productivity and quality as competition in the coatings sector intensifies. A successful research programme cannot be undertaken without a reliable record of current production performance. Furthermore, we are in the midst of the fourth industrial revolution, and all manufacturers must adapt to Industry 4.0 at some point. This requires digitalization of the wet grinding process, the core process in production facilities.

1. Introduction

Wet grinding is a demanding process. With machines operating with the smallest beads, high flow rates and maximum power input, equipment increasingly performs at the highest possible capacity. To maintain sustainable high performance, the automation solution must provide high process control and continuous monitoring of critical process parameters.

2. SmartPro

SmartPro™ is Bühler's solution to digitalize the wet grinding process to achieve higher traceability, better process control and benchmarking, resulting in significant production optimization. Bühler sees this development evolving in five stages. (Figure 1.) Figure 1. Bühler's five-stage development of SmartPro – digital services

2.1. Smart Automation

Premium and Premium Plus control systems represent the first stage of Bühler's digitalization. (Figure 2) They provide a premier solution with PLC and touchscreen. A new user interface with PLC programming and touchscreen enables easy and intuitive machine operation. Job-related analysis and diagnosis of operating data inform the operator about machine status. This offers several benefits for the industry: 1. Intuitive design for maximum productivity. The intuitive design and user guidance simplify correct machine operation. The control is user-friendly, making extensive training unnecessary. Additionally, a walk-by screen with color coding displays warnings and shutdowns at a glance, even from a distance. 2. Ideal handling of product and machine for optimal profitability. Bühler control systems allow the machine to be utilized to its full capacity. An intelligent cockpit displays current process parameters including the optimal operating range, enabling immediate adjustment. Additional features such as a job wizard support correct and rapid machine startup. 3. Auxiliary features for higher process reliability. Integrated recipe assistants enable production processes with continuous adjustment of process parameters to changing product characteristics. The result is higher process reliability in less time. 4. Detailed data management for quality assurance. The control system uses intelligent data management for quality assurance and optimization. Users can access the past 200 jobs, allowing replication and traceability of production. Additionally, to enable preventive machine maintenance, occurring errors are tracked and ranked. This facilitates easy maintenance scheduling. 5. Remote access for easy process monitoring. The Premium Plus solution provides remote access to the control system, significantly improving process monitoring. Shutdowns are detected more quickly and can potentially be resolved without on-site presence. This reduces costs and increases productivity. When required, Bühler Customer Service representatives can remotely access the system, ensuring quick and cost-effective servicing. Figure 2. Main screenshot of a premium control HMI 2.2 Smart Visualization Smart Visualization aims to make machine data available anywhere and anytime. Operators and even top management can always monitor machine actual values as well as trends via tablets or mobile phones. Furthermore, remote access and control are also possible depending on user permissions. Users can even set alarm thresholds via this tool and receive alerts by SMS and/or email. A screenshot of the SmartPro cockpit can be seen in Figure 3. Figure 3. A screenshot of the SmartPro cockpit

2.3 Smart Statistics

You can analyze your machine data and use it to optimize the production process. Like using a smartwatch to improve your running performance, at this stage long-term statistics, internal benchmarking, industrial benchmarking and data export become possible.

2.4 Smart Machine & Plants

At this stage all machines and even plants will be connected to each other through the cloud. The machine continuously checks its parameters and improves process parameters by optimizing production.

3. Conclusion

You must be able to rely on your processes. They need to run smoothly and manage countless demands, such as maximum product safety, efficient energy use and easy operation. As a solution provider with decades of experience in automation, Bühler sets industry standards and delivers the highest possible quality. All this digitalization offers certain benefits for the industry: 1. Higher productivity, a. Increasing uptime, b. Shorter reaction time for maintenance, 2. Reduced costs, a. Avoiding unnecessary maintenance visits, b. Reduction of external maintenance costs, 3. Quality assurance, a. Production traceability and documentation, b. Reduced claim costs from customers, 4. Process safety, a. Prediction of possible failures, b. Early detection of abnormalities. Aybars Kaya - Area Sales Manager (Turkey), Grinding and Dispersion Unit, Bühler Satış ve Servis Hizmetleri Tic. Ltd. Şti. (Bühler Turkey)