| Project Description:
Automate the manually intensive process of filling gas cylinders
and performing final product analysis. Cylinders were to be
filled by weight with predefined mixtures of gases using standardized "recipes." Additionally, equipment was required to monitor pressure, temperature,
and filling conditions.
Approach:
An 8 bay system capable of simultaneously filling 4 units
was designed, installed, and tested at the customer's
site. The
automation equipment selected included the following:
| • |
Intellution FIX32
SCADA system |
| • |
Allen Bradley SLC 5/03 PLC |
| • |
BASIC module for serial communication |
| • |
Mettler-Toledo Jaguar
Scale Interface |
| • |
VALCO multi-position
rotary valves |
| • |
Analyzers |
| |
 |
Rosemont NGA |
| |
|
Thermco |
| |
|
Meeco Aquamatic |
Results:
Using the manual system, the customer was originally able
to fill less than 300 cylinders daily. Automation of the
process
increased plant capacity to greater than 1,000 cylinders
per day. Additionally, the customer was able to reduce
the number
of operators from four to two on a given shift enabling
a third shift to be employed. The system also assumed the
responsibility
of product analysis, formally performed by the lab technician.
After
one year of production the customer requested the addition
of automatic quality analysis records and cylinder tracking.
This modification greatly reduced the paper records required
and simplified historical recollection. |
