OEM & System Integration Newsletter 8 (US Version)

OEM & System Integration Newsletter 8 (US Version)
OEM & System
Integration
Weighing Components
Efficient Operation and Maintenance
Relies on Streamlined Equipment
Dunn-Edwards selected METTLER TOLEDO as their sup­plier for weighing equipment
because it could provide a complete weighing solu­tion with a minimum number of
compo­nents. The IND780 terminal was chosen as sole local controller and data
transmitter for all weighing applications. This versatile terminal processes accurate
weight data and communicates with the PLC via Modbus TCP/IP Fieldbus system.
Dunn-Edwards is a leading manufacturer and supplier of architectural and industrial coatings in the Southwestern
United States. Their paints are manufactured exclusively in the Southwest and
formulated specifically for the climate of
this region.
Customized, green and
fully automatic
In June 2011, Dunn-Edwards consolidated all its operations by opening the
world’s first LEED-certified (Leadership
in Energy and Environmental Design)
paint manufacturing facility. Located in
Phoenix, Arizona, this ultra-modern facility encompasses manufacturing, development and distribution. The new
plant is fully automated, and every step
in the manufacturing process is con-
trolled by dual computer networks in order to achieve redundancy. Many of
Dunn-Edwards’ manufacturing processes are unique to the coatings industry,
and a majority of the equipment is customized to precise specifications.
Benefits of streamlined
installation
METTLER TOLEDO was selected as their
supplier for weighing equipment because
it could provide a complete weighing solution with a minimum number of components. One of the key components is
the versatile IND780 weighing terminal.
It is used as dosing and batching controllers on tank and floor scales. The terminals communicate with the PLC via the
Modbus TCP/IP Fieldbus system. The
IND780 terminal is also used on the
8
News
Tank Weighing
truck scale for weighing bulk materials
as they enter the plant and finished product leaving the plant. The bulk materials
are pumped out of the truck into large
holding tanks. From there the materials
are eventually mixed in both small and
large processing tanks supported by
METTLER TOLEDO Flexmount® and
Pinmount® weigh modules.
The solution developed by METTLER
TOLEDO complies with the requirements
for the automatic process and ensures
high quality paint products while reducing costs from inaccurate mixing. Dunn
Edwards has a streamlined installation
of weighing equipment with a small variety of components. This reduces training
efforts for operators and maintenance
personnel.
IND780 Process Terminal
The IND780 Terminal with colored TFT display controls up to 4 scales with ultrafast A/D conversion and
I/O update rate. It has optional application software
for batching, formualtion, vehicle weighing and customized applications.
www.mt.com/IND780
SWC515 Pinmount Weigh Module
Capacity: 7.5 t to 50 t
Approvals: OIML, NTEP, ATEX, FM.
Material: Stainless steel 304 and 316, plated steel.
The SWC515 Pinmount provides an extraordinary high
level of safety and accuracy. All safety related fixtures
are present in duplicate. Two optional stabilizers can
be applied to stabilize a tank which is subject to vibration or mixer torque. Thermal
expansion is possible via a Rocker Pin to guarantee best weighing performance.
www.mt.com/pinmount
0958 Flexmount™ Weigh Module
Capacity: 110 kg to 20.4 t
Approvals: OIML, NTEP, ATEX, FM, CSA.
Material: 304 stainless steel.
Clay Fenstermaker, Director of Engineering, applauded: “The level of customer
service provided by METTLER TOLEDO
was exceptional. I was very happy with
what they were able to pull off”.
For static weighing with options to allow tank expansion.
The anti-uplift bolt restrains the tank from tipping over and
can also be used to jack empty tanks for service.
www.mt.com/flexmount
Streamline your weighing equipment
when you upgrade or enhance production facilities. METTLER TOLEDO’s experts are ready to consult you.
www.dunnedwards.com
Publisher / Production
Mettler-Toledo AG
MarCom Industrial
Heuwinkelstrasse
CH-8606 Nänikon
Switzerland
Subject to technical changes
© 02/2012 Mettler-Toledo AG
Printed in the USA
2
METTLER TOLEDO
Newsletters 1/2012
Webinar – Learn About Accurate Tank Weighing
The planning and installation of tank weighing systems
are important phases in achieving the required accuracy
level in your process. Topics such as safety, correct piping
and calibration are the subject of this Webinar; view it to
learn how to make the best choices.
On Demand Webinar
www.mt.com/webinar-ind-tank-weighing
Tips & Tricks
Using pre-calibrated load cells, CalFree™ is an economical and easy way to perform
scale calibration and it yields good results. It is the perfect solution for the calibration of
large tanks and silos when placing test weights is simply impossible, or when an approximate calibration is sufficient. The method is independent of material type, density and
environmental conditions such as temperature and vibration.
Learn to Optimally
Use and Apply Weigh
Modules
Weigh Module Systems
Fast, Practical and Appropriate
Calibrating Tanks without Weights
Weigh Module Systems
Handbook
CalFree™ from METTLER TOLEDO is a
calibration method that is less accurate
than using test weights, however, it offers
a solution for calibrating scales for tanks,
vessels, silos and hoppers where it is impractical to place test weights or for applications which need an approximate
calibration only.
of the overall system. Furthermore it is
possible to replace a load cell or terminal
quickly by calibrating by this method.
Trust the gravimetrical calibration. CalFree™ is an appropriate method if calibration weights can’t be applied.
www.mt.com/calfree
CalFree™ relies on factory calibrated
load cells and terminals. The output signal of individual load cells is adjusted
within tight tolerances in production and
is recorded and supplied with each load
cell. The outputs of the individual load
cells in a scale are averaged and entered
into a weighing terminal from METTLER
TOLEDO with a calibrated A/D converter
and CalFree™ functionality. The terminal uses this average output to compute a
theoretical calibration.
The Weigh Module System Handbook
is for the engineering, operations or
integration specialist who wants a
complete set of recommendations regarding the application and use of
weigh modules on tanks, vessels, silos, hoppers, conveyors and platform
scales. It covers design calculations,
thermal effects, piping connections,
designing of support structures and
calibration.
www.mt.com/ind-system-handbook
Users who only need an approximate
calibration would find this method useful to confirm the operational integrity
METTLER TOLEDO
Newsletters 1/2012
3
Filling of Pharmaceuticals
Big and Small on One Machine
The Reason for Being Cutting Edge
The German filling machine manufacturer groninger used the new WMS Weigh Modules
to create a compact and scalable weighing system with multiple tracks. It weighs very
small and very large vials fast and accurately on the same machine. In addition the
weigh modules carry heavy preload caused by the special weighing pan.
Groninger is a success story. For many years, it has been one of the world‘s leading
companies in the field of filling and packaging machine technology for pharmaceuticals and cosmetics. Their position as leader is based on the innovative
work by their engineers and close collaboration with users. An efficient service
organization helps customers with startup, validation and maintenance.
Their filling machines for syringes, bottles and vials with volumes up to 1 liter
can fill up to 60,000 items per hour. The­
se machines offer 100% in process control (IPC) by weighing all filled vials, as
is required incre­
asingly often by the
4
METTLER TOLEDO
Newsletters 1/2012
pharmaceutical industry. Their fast cadence and requirement to fill small and
large containers on one machine place
heavy demands on the performance of
the incorporated weighing technology.
High quality at all levels of the company
is one of many factors contributing to the
success of groninger. However, these high
quality requirements also affect suppliers. METTLER TOLEDO has been a reliable supplier of accurate weighing technology for many years. The strong performance of the WM weigh module product
line was appreciated by groninger for several years. Its high level of accuracy
combined with a high weighing capacity
facilitates accurate weight control for all
sizes of pharmaceutical packaging on
the same machine.
New WMS weigh module meets
even tougher requirements
A recent demand for an exceptionally
multi-faceted, high-speed machine required a weighing range higher than the
510 g for the WM503 weigh module previously used. The limited amount of space
available also meant a reduced overall
width was necessary. METTLER TOLEDO
was in a position to present the new WMS
weigh modules to groninger at this very
moment. The WMS1203C meets the tougher requirements in every respect. It has
Best Practice
Simple and Fast
Connection to PLC
Use METTLER TOLEDO Fieldbus modules for fast commissioning. They
can be mounted on Din-rails and offer auto-detection of parameters. You
will significantly shorten integration
time and save valuable resources.
high readability and reproducibility of
1 mg across the entire weighing range of
1200 g. This makes it capable of carrying
a special heavy weighing pan for various
container formats and for weighing both
small and large containers accurately.
When the requirements are such, the approximate weighing time is a mere 0.3
seconds per weighing process. Despite the
high-speed weighing technology, several
modules needed to be arranged in parallel to be able to reliably check the entire
output of the machine. For this reason,
groninger integrated several WMS weigh
modules in one parallel row with a track
width of 30 mm. The arrangement in this
limited amount of space led to an eccentric load pick-up by the weigh module, but
this did not adversely affect the level of
accuracy. The weigh module also has a
built-in calibration weight, ensuring that
the smooth functioning can be inspected
at any time, even when a special weighing
pan is fitted.
Top marks all-round:
Engineers from groninger, by employing
multiple WMS weigh modules in parallel,
have turned a scalable weighing system
into a reality. Individual weighing points
can be added or removed from the machine without any problem. In the event
of a failure, the local service technician
will replace the affected module in just a
few simple steps. The high weighing capacity and the option of eccentric load pickup support the use of attachment equipment, without restricting the vial volume.
With the new WMS weigh module, groninger has a complete weighing technology solution. The company will be able to
use this to react to future market requirements or take the market by surprise with
their own innovations.
www.mt.com/ind-apw-fieldbus
Speed up your filling process with this
fast and accurate weighing technology.
www.groninger.de
WMS1203C Weigh module
Readability: 1 mg
Capacity: 1210 g
Stabilization time: 0.15 – 0.8 sec.
Stainless steel housing
Integrated calibration weight
Can be cleaned thanks to IP66 protection
www.mt.com/WMS
METTLER TOLEDO
Newsletters 1/2012
5
Weight Based Quality Control
High Throughput
Despite 100% Inspection
The manufacturing process for solar cells consists of a multitude of individual steps. A
weight check between each step ensures that only good wafers proceed to the next treatment. METTLER TOLEDO has the right products and the expertise to support machine
builders in successfully applying weight based quality control for solar cells.
The transformation process from a
block casted poly-crystalline silicon ingot to a solar cell consists of several individual steps. It starts with cutting and
shaping the ingots into wafers. Then the
wafers have to pass through several
etching, coating and printing processes
until it is a solar cell with the capability
to produce electricity. A strict quality
control check at the end of each treatment ensures only good wafers proceed
to the next production step.
Weight based quality control
Measuring the weight before and after
each production step is a fast and reliable
quality check. It allows for detecting de-
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METTLER TOLEDO
Newsletters 1/2012
viations in geometry, completeness and
density of the wafer before surface treatment starts. Then the weight difference is
used for checking results of etching,
coating and printing. It requires weigh
modules with repeatable precision between 10 mg and 0.1 mg.
One weigh module for all steps
METTLER TOLEDO’s high precision
weigh modules comply with the requirements. They can reliably detect deviations of less then 1 mg in a fraction of a
second. The WMS104C is the most often
used weigh module for quality control in
silicium based solar cell production. It
has a readability of 0.1 mg and the re-
peatability of 0.2 mg. The software applies filter algorithms to measure correct
and repeatable results in spite of vibrations from machines and draft from the
air conditioning system. An incorporated
calibration weight allows testing of correct function without need to remove the
hosting adapter for the wafer.
Fast communication to
keep the pace
The fast interface sends 92 filtered and
compensated weight values per second to
the control system. The transmitted data
can be converted to all common Fieldbus
Systems if required.
Simplified production process.
(Complementary quality control technologies to weighing are not shown).
Consultancy ensures successful
implementation
However, correct integration of weigh
modules is key for the successful use of
weighing technology in a solar wafer production process, since a number of challenging environmental effects have to be
taken into account. A close cooperation
during the design process between machine builders and the experts of METTLER
TOLEDO ensures achievement of optimum performance.
Reference weight of the
workpiece: w(wp) = A
Process Step adding or
subtracting material
of nominal weight plus tolerance
w(n) = e +/- Δe *
control. It can be applied to detect the
smallest deviations in assembling, molding, coating, etching and printing processes for many products. METTLER
TOLEDO has its own direct service and
sales force. Its experts are globally available for consulting customers in correct
integration of weigh modules into any
kind of quality control applications.
Ask METTLER TOLEDO how weight
based quality control can increase yield
in your production.
Weight based quality control is
not limited to solar cells
Manufacturing of solar cells is not the
only application for weight based quality
www.mt.com/WMS
WMS104C Weigh Module
Post process weight of the
workpiece: w(wp)´= B
Readability: 0.1 mg
Capacity: 120 g
Settling time: 0.15 – 0.8 Sec.
Labyrinth in IP54 protects against
ingress of dust particles
Wash-Down option in IP66 for cleaning
with fluids
www.mt.com/WMS
Workpiece is
<0
withinDT
tolerance
|B – A – e| < Δe
No
Waste or
Repair
Adapt process
parameters
Yes
Next Process Step
* e may be a positive value in case of adding material (e.g. coating) or a negative number in case of
subtracting material (e.g. etching)
METTLER TOLEDO
Newsletters 1/2012
7
Download More Information
Weighing Components Brochure
For Machine and Instrument Builders
The new brochure addresses machine and
instrument builders. It presents a comprehensive range of load cells, weigh modules and terminals covering everything
between 11 g and 300 t. The lowest readability is 1 μg. The control electronics
ranges from simple weight transmitters
for fitting on DIN rails up to sophisticated
terminals for batch controlling.
You can order the new catalog under the
link below.
www.mt.com/ind-brochure-components
Battery-powered Terminal
Portability in hazardous areas
IECEx
The IND560x intrinsically safe terminal
is now available with a NiMH battery pack
for use in hazardous areas where portability is desired. The battery-powered terminal supports many options - discrete
inputs and passive outputs for direct con8
METTLER TOLEDO
Newsletters 1/2012
trol of intrinsically safe solenoids, PLC
interfaces for connectivity and software
pacs for advanced filling, vehicle weighing and custom communications capabilities.
www.mt.com/IND560x
Higher Uptime for Tank Scales
Economical Use of Raw Materials
A new fully digital load cell with preventive maintenance functionality can increase uptime and provides more weighing accuracy. The internal microprocessor self-monitors
the load cell and compensates weight results for environmental influences. This technology helps to prevent losses of raw material while minimizing bad batches and downtime.
The new POWERCELL® PDX® load cell
inside the Pinmount weigh module is
truly digital. It hosts an on-board microprocessor to monitor internal and external influences that affect weighing accuracy. By compensating for temperature
changes, vibrations, hysteresis and nonlinearity, the microprocessor enables the
individual load cell to provide extraordinary accurate results.
True predictive maintenance
The self monitoring POWERCELL® PDX®
load cell maintains weighing accuracy
by alerting if problems inside the load
cell or within the network arise. A builtin breach detection system alerts if the
enclosure is damaged by accidental
puncture or tampering. The breach detection system allows the replacement of
a load cell at the first sign of trouble,
before e.g. moisture causes weighing errors or scale failure. This kind of predictive diagnostics increases uptime and
prevents users from loss of raw material,
bad batches or even stopping the entire
production process. With the POWERCELL® PDX® load cell system, time-consuming troubleshooting and parts swapping are replaced by prevention.
With POWERCELL® PDX® load cells,
electronic components are protected inside the hermetically sealed load cell enclosures. The quick-connect design
makes it easy to replace individual load
cells or cables. There is no need to recalibrate the scale if a cable is replaced.
POWERCELL® PDX® load cells connect to
one another in a simple network, eliminating junction boxes. In analog systems, sensitive electronics are located in
junction boxes, which are prone to failure and hard to seal against moisture.
The POWERCELL® PDX® load cell, including all cables and connectors, is
watertight- even when submerged, effectively sealing the entire network
against moisture to IP68 standards.
Avoid loss of material, bad batches or stopping the production process. Secure the
performance of your tank scales by relying
on POWERCELL® PDX® digital load cells.
www.mt.com/ind-pinmount-pdx
Pinmount PDX® Weigh Module
Capacity: 20 t, 30 t, 50 t
Resolution: 3000e, 4000e, 10.000d
OIML approval: C3 and C4
NTEP approval: IIIL 10.000d
ATEX approval: Zone 2/22
Material: zinc plated or
304 Stainless Steel
POWERCELL® PDX® load cell.
www.mt.com/ind-pinmount-pdx
METTLER TOLEDO
Newsletters 1/2012
9
WMC Weigh Module
Verify Fit Inside Your Machine
Get Inspired for New Applications
The dimension of the WMC weigh module is only 25 mm wide,
74.5 mm high and 65 mm deep. You can download 3D CAD data
in STEP format to verify if the weigh module fits into your machine. Alternatively fold the pattern below and you’ll have an
exact size model that you can place into your machine! You can
also download a PDF with the pattern below, if you need more
then one paper model.
Use the link below for downloading 3D-CAD-Data and pattern
for paper model:
www.mt.com/ind-WMC-CAD-Data
Scale: 1 : 1
Glue
Glue
Glue
-------Fold
––––– Cut
Glue
Glue
Glue
Glue
Glue
Glue
10
METTLER TOLEDO
Newsletters 1/2012
Award Honors Innovation
Compact, Fast and Accurate
The innovative WMC weigh module is the perfect combination of a compact desing, speed
and high accuracy. It exceeds the known performance for such modules and enables
completely new applications. These features convinced the jury for the innovation award
at the international Powtech Fair: They nominated the WMC Weigh Module as the best
product in measuring and control technology.
The high-precision WMC weigh module
is ultra compact and rugged by design. As
such, it is suitable for semi- and fullyautomatic processes, as well as for manual weighing, wherever space is at a premium. The small size enables machine
manufacturers to build arrays with a
minimal pitch. This facilitates the placement of numerous weigh modules on a
small space to form a compact array for
parallel multi line filling or check weighing. It speeds up the entire process if
multiples of vials, ampoules, syringes,
tablets or capsules are weighed in parallel on such an array within fractions of a
second. With this allocation of weigh
modules it is even possible to accurately
weigh with throughput rates of >10’000
units per hour. The number of weigh
modules in an array has no limits. It can
range from two to dozens of modules.
The fact that such an array consists of
independent modules makes it easy to replace one when a repair or service is required.
Innovation-Award at POWTECH/
TechnoPharm Fair 2011
The “PROCESS”, “PharmaTEC” and
“Schüttgut” magazines awarded innovations at the international POWTECH/
TechnoPharm fairs in October 2011 in
Nurenberg Germany. The criteria were:
Grade of innovation, quality, efficiency
and economics for users. More information under:
www.process.de
WMC Weigh Modules:
Capacities:
11 g or 21 g
Readabilities:
0.1 mg or 0.01 mg
Dimensions:
(l x w x h): 65 x 25 x 73 mm
2.56 x 1 x 2.93 inch
Serial Interfaces: RS232
Fieldbus Interfaces: DeviceNet™, Profibus®,
ControlNet™, EtherNet/IP™
Ethernet TCP/IP
www.mt.com/WMC
Ulrich Kuhlmann, Sales Manager OEM/SI from Mettler Toledo Germany,
proudly presents the trophy for the Innovation Award in the category
Measuring-and Control Technology for Automation.
METTLER TOLEDO
Newsletters 1/2012
11
Use www.mt.com as a
Work Efficiency Resource
Register for Free On Demand Seminars
Webinar – Learn about Accurate Tank Weighing
The planning and installation of tank weighing systems are critical phases in achieving the required accuracy level in your process. Topics such as
safety, correct piping and calibration are the subject of this Webinar; view
it to learn how to make the best choices.
www.mt.com/webinar-ind-tank-weighing
Download Comprehensive Product Documentation
Increase Productivity and be Compliant
Weighing and measuring are critical for manufacturing productivity and
food safety in many production operations. Our two new guides help you to
make informed decisions when selecting the right weighing technology
and product inspection method.
FREE
FREE
www.mt.com/ind-food-productivity-guide
www.mt.com/ind-food-regulatory-guide
Productivity Guide
Regulatory Guide
www.mt.com/ind-weighing-components
For more information
USA
Mettler-Toledo, LLC
1900 Polaris Parkway
Columbus, OH, 43240
Tel. (1) 800 523 5123
USA
Mettler-Toledo Hi-Speed
5 Barr Road
Ithaca, NY, 14850
Tel. (1) 800 836 0836
USA
Mettler-Toledo Safeline
6005 Benjamin Road
Tampa, Florida, 33634
Tel. (1) 800 447 4439
Canada
Mettler-Toledo, Inc.
2915 Argentia Road, Unit 6
Mississauga, Ontario, L5N 8G6
Tel. (1) 905 821 4200
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