SIPA machine data acquisition & analytics software
Problem
Customer’s SIPA extrusion blow molding machine required extensive process optimization in order to reduce significant amount of out-of-spec parts (bottles) during startup, warmup. and production running stages. No standard data acquisition or analytics add-ons were available to perform the necessary complex data captures and post-processing analytics.
Solution
Novum Automation, utilizing PROMEA, designed, developed, installed, and commissioned a completely unique and highly complex data acquisition and analytics system onto a pre-existing SIPA machine in order to capture over 1,000 unique machine and part data points in real-time and for post-processing. Based on the acquired data and analytics, the customer was able to determine critical process parameters that were affecting part characteristics in order to drastically reduce failing parts.
Developed 4-axis servo motor control system for inserting measurement apparatus directly into preforms, rotating preforms 360 degrees, then lifting apparatus
Performed synchronization of preform angular position (clocking) during rotation with non-contact IR sensor temperature data in order to attain a fully representative 360-degree temperature profile of the plastic preform
Data acquisition system incorporated five TSN enabled NI cDAQ chassis’ to maintain high-speed data synchronization between remote cDAQ chassis & C-series modules
Acquired non-contact preform thickness by utilizing Keyence CL3000 controller and CL-P070 sensors to gather 360-degree wall thickness profile of specific preforms
Temperature measurement system used integrated Micro Epsilon CT-fast non-contact IR sensors (NCIR) for capturing high-speed temperature measurements of preforms
Developed custom LabVIEW software utilizing Delacor Queued Message Handler (DQMH) framework to provide for highly scalable and maintainable code. Over 30 custom modules were developed, with several being clone-able modules (e.g. graphs, charts)
Built standalone .exe to allow NI OPC server to run separately from main code and allow transfer of data to Kepware server for further processing with Tableau
Based on Novum’s standard PROMEA product offering (with application-specific development)
