Mechanical Systems

Parijat Aluminum Extrusion SCADA

The goal for extrusion operations is to produce the highest quality product at the lowest possible cost. Securing this efficiently requires a change in paradigm from operators pushing buttons and manually collecting data – to presses running in complete automatic, performance and production data being collected and transferred to the business, ERP system, while the equipment operators function as technicians concentrating on improving quality and productivity. The MIS, ERP system may be an existing 3rd party system like SAP, Oracle Financials, M2M, InFor, MS Dynamics, Epics etc. or it may be the integrated business systems option of the Parijat system.A Typical aluminum extrusion system solution consists of various software silos or islands from different vendors software products with multiple copies of data, also requiring a lot of manual data entry activities that are prone to human errors.PCI solution combines all of these activities into a single software application with a single copy of data. This eliminates any data integrity complications & vulnerability to human data entry errors.
AutomationTo get to this level, the press system – beginning with the billet / log heating and cutting system; billet loading system; press cycle, auto Die change; lead out table / hot saw / puller; profile handling transfer / stretching system; Cold / finish saw infeed, cutting, queuing, and offloading systems must be balanced; quenching air / water; PLC’s capable of communicating between themselves, running in automatic closed loop control mode and the PLC’s making process adjustments based on equipment settings, positions and computer algorithms all with minimal operator intervention.Finish saw automation, unattended operation after the stretcher trim is cut off so the saw operator can assist in racking metal.Tracking & TraceabilityUse advanced video analytics, Blockchain & I-iot (Industrial Internet of Things), Industry 4.0 to track & trace the materials used from entry of logs/billets to the finished products at plant exits.Communications – data collectionUp till now data collection and analysis was quite arduous – many times data is not thoroughly collected or analyzed to determine what is preventing current system from running optimally – getting to root cause is the key. Even the oldest presses have the potential to run in full automatic or as a bare minimum semi-automatic. Parijat SCADA data collection system will provide with real time press performance and identify roadblocks to excellence. Parijat integrated single system will provide the cost savings models by modifying or correcting the issues which are keeping the press from being very profitable.Once the press system is functioning at full potential, optimum recipes (press parameters) can be generated beginning with the highest volume shapes. These recipes get automatically pushed directly into PLC’s, once again reducing operator keystrokes and potential for human error. Infinite quantity & extensive recipe management system helps with the process optimization also. Parijat PLC programs & the PC software harness the full power of both sides coupled with the domain knowledge of Aluminum extrusion.