Conair Implementing a Common Control Platform For All Its Plastics Auxiliary Equipment

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Aiming to deliver a more consistent user experience and make it easier for employees to learn the operation of multiple types of auxiliary equipment, Conair is rolling out a new control platform, featuring an HMI that offers a consistent user experience regardless of the machinery involved. The new control platform and HMI have already been implemented in the SmartFLX™ material handling control, truck-fill line-proofing system, blenders, and temperature-control units, with dryers scheduled to be released in Q3 and chillers and other equipment to follow. Other systems, such as Wave Conveying and Conair’s new RFID-proofed resin-selection system are controlled through the SmartFLX Platform.

In addition, all are compatible with SmartServices™, Conair’s cloud-based IoT or “Industry 4.0” solution for machine monitoring and data collection. The Machine Control portion of SmartServices mirrors the same control screen that an on-the-floor operator would see. So, anyone logging into the SmartServices dashboard and using the Machine Control feature will be familiar with the screen setup, and basic operation of the various pieces of connected equipment.

“Having a universal control system on our equipment, will further differentiate Conair in the competitive landscape,” explains Sam Rajkovich, Vice President, Sales & Marketing, “and, more importantly, it will give a leg up to processors. All the buttons will be in the same place, with the same names and color schemes, which will require very little training for an operator as they train on different equipment. We have had that in the past, but only within product lines and not across our full equipment offering.  We believe this is the first time any supplier has offered all the major pieces of equipment and central control systems with a common, consistent look and feel from the operator’s perspective.”

Even with the common interface, different auxiliary equipment will continue to use screens of different sizes — 4.3, 7, 10, 15 inches, and so on – since the complexity and detail of control varies depending on the equipment type.  Blender controls, for instance, require more functionality than temperature control units and so the way information is displayed might change. However, the menu structure and navigation, set-point entry, alarm notification, icons, colors, communication protocols, and back-end hardware remain essentially the same.

FUTURE PROOFED

The OPC Unified Architecture (OPC UA) data-exchange standard is the primary protocol for Conair machine controls moving forward and will be standard in all touchscreen-based controls. Since few processors are actually using OPC UA, MODBUS and other standards also continue to be supported. However, when the plastics industry reaches a point where OPC UA becomes the primary machine-to-machine or machine-to-PC communications protocol, the Conair controls will be ready and implementation of true Industry 4.0 practices will be easier than ever.

“Managing rapidly-changing technology is a challenge for our customers as well as for Conair,” says Matt Shope, Director of Engineering. “By leveraging a common control platform, we can implement new features, new hardware, and future-proof communications across all our products with minimal risk to the customer.”

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Conair PipeMaster™ Line Offers Cost-Effective Solution for Processing Extruded Plastic Pipe to Over 2 Feet in Diameter

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Aiming at a larger share of the equipment market for extruded PVC and polyolefin plastic pipe, Conair is introducing PipeMaster™, a complete line of downstream processing equipment and tooling that offers rugged, reliable, and cost-efficient performance in six size ranges for pipe diameters from 0.4 to 24.9 inches (10 to 630 mm) in up to 5-layer construction.

The line represents a big change for Conair, whose range of pipe processing equipment has, until now, served sizes of 8 in (200 mm) or less, says Ernie Preiato, Vice President, Extrusion for Conair and a 33-year veteran of the extrusion field.  “We understand that extruded pipe processors compete in a very robust and cost-conscious market and can choose equipment from all over the world, with various levels of quality and price points. Our feedback from processors was that they wanted a reliable U.S. source for equipment that delivers high-end quality, output, service and support, but without the huge price tag.”

Preiato explains that the key to Conair’s new, competitively priced PipeMaster line is found in its simplicity and attention to the fundamental needs of processors:  “This equipment – spray tanks, puller/haul-off units, saw cutters, and drop-off tables – combines very rugged construction with simple, but well-engineered controls. It is complemented by an extensive range of the extruder tooling, including pipe dies and calibration sleeves, that most processors need but often have difficulty finding or building at a competitive price.  And, the entire PipeMaster line is backed by Conair’s factory service and support.”

Preiato went on to detail the elements of the Pipe Master line, which includes:

  • Monolayer and multilayer pipe extrusion dies optimized to different material types (PE/PP, PVC and others), and for pipe diameter ranges of 2.5, 4.3, 6.2, 9.8, 15.7 and 24.9 in (63, 110, 160, 250, 400 and 630mm). Each die is mounted on a movable, height-adjustable stand and features polished, heat-treated internal surfaces. Interchangeable die pins and nozzles allow dies to produce multiple sizes of pipe. Multilayer extrusion dies can extrude up to five layers in a single pipe.
  • Output rates ranging from 550 to 3520 lb/hr (250 to 1600kgs/hr).
  • A full range of pipe calibration tools, with options for dry sizing or water-ring cooling and sizing.
  • Vacuum immersion, vacuum-spray, or immersion-only cooling tanks with single or dual chambers. All tanks feature 304 stainless steel construction on internal/wetted surfaces, durable painted-steel exterior surfaces, simple frame-mounted controls and fully-adjustable stands.
  • Cleated puller/haul-off units that automatically synchronize speed with extruder screw speed control and integrate with gravimetric material dosing for stable production and consistent pipe unit weight. Inside each puller’s fully-enclosed safety cabinet, brushless AC vector motors provide steady pulling force using soft, non-marking cleated pads.
  • Servo-driven pipe cutting units, also synchronized to line speed, which measure and cut pipe in a variety of lengths to meet application requirements. Multiple cutter types accommodate different pipe sizes and application requirements, including rotating disc cutters for chipless displacement cuts and planetary cutters for milled or chamfered cuts.
  • Pneumatically operated pipe tilting/dump off tables synchronize with line speed to receive and automatically dump finished pipe lengths into stacks for easy removal, packaging, shipment or storage.

According to Preiato, Conair is building a new 6-inch plastic pipe extrusion line at its extrusion laboratory and pilot plant in Pinconning, Michigan, and plans a live demonstration of the new line and its PipeMaster downstream processing equipment in early June.  Conair will also highlight PipeMaster equipment at a customer open house in Pinconning later in 2021.  Details of both events will be announced soon and made available at conairgroup.com.

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Conair SmartServices™ Adds Grouping, KPI, and Resin Usage Features, Plus Common Interface for Remote Machine Control

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The latest version of SmartServices™, Conair’s cloud-based Industry 4.0 solution for connecting, monitoring, and managing auxiliary equipment, adds new features that give processors added flexibility in equipment monitoring, expanded integration capabilities with non-Conair controls, and a common interface for remote auxiliary equipment control.  All of these additions mark Conair’s continued effort to realize the Industry 4.0 goal of exchanging standardized data across machine types and achieving machine-to-machine and machine-to-PC connectivity.

Thanks to expanded naming, grouping, and sub-grouping features, processors can now name and organize equipment and equipment groups for SmartServices monitoring and management in virtually any way they  wish—by plant, process, line, or equipment type. These expanded options give processors flexibility to create time-saving scans that “roll up” performance trends, KPIs, maintenance alerts, or priority alarms within a single large equipment grouping. Then, if additional details are required, processors can dig deeper, scanning through varied or specialized subgroups, such as all dryers, all auxiliaries that serve a specific production line, or all TCUs that are due for preventive maintenance.

SmartServices has also expanded its array of real-time trending and Key Performance Indicators (KPIs). Instead of displaying a default set of 3 KPIs for each machine type, SmartServices now offers 10 customizable KPIs and enables users to customize and rank-order all 10 for time-saving, at-a-glance monitoring.

Another new feature, delivered in combination with blender-data logging, simplifies inventory management and production vs. scrap calculations by tracking and storing resin usage and providing on-demand, or scheduled usage reports by blender, or by resin name. What’s new is the fact that these functions are now integrated into the SmartServices platform, which automatically does all software and hardware server-related installation and maintenance of the data.  SmartServices then totals information from each blender and stores this data in the cloud, like any KPI or other measurement.  The user can then run the resin reports.

Standardized displays, built with non-standardized data
Routine exchange of standardized equipment data is a foundational element of Industry 4.0. However, the protocol for data standardization – OPC UA – is only now being created for plastics machinery controls, so wide-scale adoption by processors is not yet possible.

To bridge this gap and enable the organized presentation of data from auxiliaries not built by Conair, the SmartServices team performs its own custom integration work. This involves reading the data streams of other auxiliary controls that use MODBUS, pulling out relevant data, and integrating it with real-time data from similar auxiliaries for presentation. Until OPC UA is widely adopted, this integration work is essential to processing varied auxiliary equipment data into the neat trend lines, statistical displays, KPIs, and clickable features common to the SmartServices interface.

But the integration effort doesn’t stop there. As Conair implements its newly announced “common” control platform and HMI for its auxiliaries, SmartServices is able to display that same common look and feel in its Machine Control view, which gives authorized users the ability to view and remotely control auxiliary equipment the same way they would on the plant floor. This enables SmartServices to deliver a common remote control interface with the SmartServices platform.

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Conair Introduces New Temperature Control Units Loaded with New Control and Connectivity Features

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Few pieces of auxiliary equipment are as basic to plastics processing as temperature control units (TCUs), and yet the newest TW Series from Conair brings a host of new features and capabilities to this “workhorse of the plastics industry.”

The Conair Thermolator® TCUs are still available in three standard configurations:

  • The TW-V (V stands for value) are offered with ¾- and 2-hp models, both with a 12kW heater and 3/8” solenoid valve. They offer a smaller footprint than previous versions.
  • TW-S mid-range units are sized from ¾ to 10-hp and the units up to 2HP also have a smaller footprint.
  • Premium TW-P comes in the same size ranges but with much more advanced features.

All the new Thermolator units feature an ergonomic angled face panel for better viewing of the HMI, and the TW-S and TW-P models are the first units available with Conair’s new “common control,” offering a consistent user experience regardless of the machinery involved. The TCU menu structure and navigation, set-point entry, alarm notification, icons, colors, communication protocols, and back-end hardware will essentially be the same as other Conair equipment, including blenders, dryers, etc. These common features simplify operator training and make it easier employees to learn to use different auxiliaries.

The new Thermolators offer one of the broadest ranges of communications options available in the industry, including Modbus RTU RS-485, Modbus TCP Ethernet and, on the TW-P, OPC UA communication enables for 21st century connectivity. The TW-P is also compatible with Conair SmartServices™, Conair’s cloud-based IoT or “Industry 4.0” solution for machine monitoring and data collection.

Mechanically, the TW-P units can be equipped with solid-state relay (SSR) heater controls that provide the highest levels of precision and long-term dependable operation. They incorporate heat sinks inside the control enclosure and include a beefed-up ventilation fan to dissipate the heat. Mechanical contactors, representing proven technology, and will continue to be offered as standard equipment on all Thermolators.

Also available are modulating valves for cooling in the place of more conventional solenoid valves, which still offer reliable performance and remain available as standard equipment. However, instead of controlling flow by periodically opening and closing like solenoid valves, the modulating valves operate from independent open and close signals so that flow is continuous but controlled. The modulating valves can be opened or closed partially in a linear fashion for greater precision and to eliminate water hammer when flow rates change.

In addition, standard programs can be loaded into the TW-P controller for easy recall. Electrical phase monitoring, an optional flow meter with HMI readout, intuitive help screens for all functions are also provided.

Logically, TW-S and TW-V feature a simpler design. The TW-V has an LCD displays and analog gages. The TW-S has the common-control HMI, with analog gauges as standard (digital optional), and many of the more advanced features of the TW-P also can be added as options.

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Sepro Group Establishes Daughter Company in Switzerland

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Sepro Group is creating a wholly owned daughter company to provide more comprehensive sales and service coverage in the country.

“Establishing Sepro Switzerland as a legal subsidiary demonstrates our commitment to customers there,” explains Xavier Lucas, Chief Sales Officer for Sepro Group. “Feedback from customers about the new organization has been really positive.”

Thomas Scherz, Area Sales Manager, leads the organization with support in the French-speaking western region of  Switzerland from Olivier Violy, a 25-year Sepro employee who also covers southeastern France. Customers in the Italian-speaking southeast of Switzerland will continue to work with Sepro’s Italian distributor, Sverital SpA. Marcus Klaputek, Sales Director for Sepro Group, also supports the Swiss organization.

The technical service organization has also been reorganized. A full-time service technician covers the German-speaking part of the country and a second technician has been tasked with supporting customers in western Switzerland, with the back-up from Sepro’s local branch in eastern France.

As a leading global supplier of robots, Sepro equips all injection-molding-machine brands from 50 to 5000 tons, whether new or already installed. Sepro’s complete solution includes robots with 3, 5 or 6 axes of motion and all are controlled by the same Visual platform.

Thomas Scherz is a Swiss national who has been involved in sales and key account service in the plastic packaging and industrial equipment industries since 2008. He trained in mechanical engineering and has a Bachelor of Science in business administration and received a Diplom-Ingenieur in sales management in 2017.

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Sepro UK Marks 30th Anniversary With Opening of Expanded Robot Sales and Service Center

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In April, Sepro UK, a daughter company of French robot maker Sepro Group, celebrates its 30th anniversary with the opening of an expanded sales and service center in Milton Keynes, Buckinghamshire.

Since its founding in 1991 as one of the first wholly-owned subsidiaries of Sepro Group, La Roche-sur-Yon, France, Sepro UK has grown with its plastics-industry customers into an important supplier of 3- and 5-axis Cartesian beam robots, and 6-axis articulated-arm robots, as well as automation systems. Its customers include injection molders that serve medical, housewares, construction materials and other markets throughout the United Kingdom.

According to General Manager Glen Eves, the new, 232 m2 sales and service center in Lodge Farm Business Centre, Castlethorpe, Milton Keynes, unites robot sales, service, parts, and robot-commissioning activities under one roof. The new facility also houses a Sepro robot training center, complete with working Cartesian and 6-axis robots, where customer technicians can receive hands-on instruction in robotic programming and control.

“Despite the difficult business challenges posed by Brexit and the current pandemic, our team of experts remain 100% dedicated to helping our injection molding customers to use robotics and automation to be more productive and successful,” said Eves, who has led Sepro UK since December 2013. He added that as Sepro UK sales have grown fourfold over the past decade, the organization has continued to focus on customers, investing in strengthening its service team and capabilities. Today, the Sepro UK staff numbers nine overall, including a technical service supervisor and three service engineers.

 

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Conair Invites Industry to Virtual Plastics Processing Technology Summit, May 18-20

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Conair, with cooperation from three other plastics industry leaders – Arburg, Milacron, and Davis-Standard – is hosting a three-day virtual event that will present not only new products, but also expert-led discussions about current market conditions and the latest processing methods and technologies on May 18, 19, and 20.

Free and open to the global plastics industry, the three-day Conair Summit 2021 offers experts hosting a series of market keynotes and technology-focused discussions, each highlighting current conditions and challenges, offering new manufacturing processes and solutions, and addressing participant questions. Live Summit presentations will occur from 10 AM – 3 PM, EDT. The agenda of discussion topics includes:

Tuesday, May 18

  • Leveraging Digital Technology to Optimize Equipment Operation & Maintenance
  • The Science Behind Smart Resin Conveying
  • Addressing Recent Trends in the Plastics Medical Device Market

Wednesday, May 19

  • Staying Competitive & Profitable in an Evolving Automotive Market
  • The Changing Extrusions Market
  • Advantages of the Groove Feed Extruder for Pipe and Profile Applications
  • Improving Size Reduction and Scrap Processing

Thursday, May 20

  • Advances in Heat Transfer Technology
  • Overcoming Challenges in Plastics Packaging Processing
  • Precise and Profitable Blending
  • Simply Smart Resin Drying

During and after the Summit, registered participants are invited to visit virtual technology exhibitions offered by the presenting companies and to revisit or share archived Summit presentations.

To review an updated Summit agenda or register for the conference, visit The Conair Summit 2021.

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Sepro Launches Packaged Robot Solutions for Medical and Pharmaceutical Applications

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To meet growing demand for automation in clean rooms and other sensitive environments in medical and pharmaceutical molding plants, Sepro Group is introducing the MED Series of 3-, 5- and 6-axis robots.

These packaged units come ready-equipped with the design and operational features that medical customers have been requesting on over 1500 molding machines sold in recent years for ISO 7 and 8 clean room applications. These features ensure clean operation as well as high precision and continuous productivity.

“Sepro robots increase productivity and enhance workflows” explains Claude Bernard, Product Marketing Director for Sepro. “Within the clean room market, our robots can be used across the entire production line – from assembly to inspection, traceability and packaging.”

The Swiss molding company, Fischer & Söhne, which produces medical and pharmaceutical products, uses Sepro robots in its clean rooms. CEO Iwan Tresch says: “With production based on the food industry standard BRC, hygiene and clean room requirements, no compromise is possible. With Sepro robots, we can increase our productivity while guaranteeing an optimal level of hygiene. Sepro is a responsive company, with fast delivery times and flexibility.”

In general, the Sepro MED robots include FDA-approved lubrication on all linear guiding surfaces and gearing. Cables can be protected in conduits and all robot surfaces are smooth, painted medical white with limited decoration so that dust does not accumulate, making cleaning easier. Only clean materials are used in many components – like end-of-arm tooling — that come into contact with the molded parts. Places where grease or other lubrication is used are enclosed so that none can escape into the molding area. 5X MED robots include a two-axis servo wrist to provide a total of five numerically controlled axes of motion. S5 Line MED robots have three servo-driven axes and a pneumatic wrist. All robots can be optionally equipped with pneumatic filtration to 0.3 micron.

CARTESIAN BEAM ROBOTS

The 5X MED and S5 Line MED ranges each include robots in three different sizes to allow them to serve molding machines with from 30 to 800 tons of clamping force. Nominal payload capacity (part plus end-of-arm tooling) ranges from 5 to 20 kg (11 to 44 lb.). The robots can be installed in a conventional transverse or space-saving axial layout. Available stroke lengths are as follows:

 

S5/5X 15 MED S5/5X 25 MED S5/5X 35 MED
Horizontal (X) mm (in) 1500 – 4000 (59 – 157) 1500 – 6000 (59 – 236) 2000 – 9000 (79 – 354)
Demolding (Y) mm (in) 500 (20) 700 (28) 900 (35)
Vertical (Z) mm (in) 1000 (39)* 1400 (55)** 1800 (71)**

* Direct Arm

** Telescopic Arm

6-AXIS ROBOTS COMPLY WITH ISO 5

Offered in collaboration with Stäubli Robotics, the Sepro 6X MED 6-axis-servo articulated-arm robots are inherently clean. The standard Staubli arms are certified for ISO 5 (Class 100) clean rooms without modification. However, the smooth, clean white surfaces make keeping them clean just that much easier. In fact, the 6X MED robots can exceed the level of cleanliness possible with injection-molding processes.

6-axis robots are typically floor mounted (but can be ceiling-mounted) and usually enter the molding machine from the side. Laminar air flow allows these installations to meet the requirements of ISO 7 and 8.

Four models are available to serve molding machines from 20 to 1300 tons.

 

6X-60 MED 6X-90 MED 6X-160 MED 6X-200 MED
360⁰ Reach

Long Arm Version

 mm (in) 670 (26)

920 (36)

 1200 (47)

1450 (57)

 1710 (67)

2010 (79)

 2194  (86)

2594  (102)
Payload kg (lb) 3.5 (7.7)

2   (4.4)

 6  (13.2)

5  (11)

 20 (44)

14 (30.8)

 100 (220)

60  (132)

In addition to 3-, 5- and 6-axis MED robots, Sepro also supplies a wide range of peripheral and downstream equipment, including end-of-arm tooling, safety guarding, conveying systems, part inspection and part separation. “Solution by Sepro” is also available to integrate multiple robots, specialized end-of-arm tooling, plus a variety of feeders (bowl, drawer or manual), , cavity separation, degating/trimming, box filling and other equipment – all customized to suit specific manufacturing objectives.

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New ECO™ Air-Cooled Chillers from Conair Offer Extreme Operational Flexibility

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Designed for outdoor installation and providing chilled water to plastics processing equipment indoors, new Conair ECO™ packaged chillers are rugged enough to function efficiently under almost any ambient conditions, while providing a process-temperature setpoint range that is among the widest in the industry.

A total of six models are available with cooling capacity ranging from 40 to 120 tons. All feature direct-drive hermetically sealed scroll compressors, proven in their reliability, low maintenance requirements and efficient operation. Dual refrigeration circuits, with multiple compressors, provide built-in redundancy, while the larger units (80 through 120 tons) also incorporate independent process fluid circuits as well. The modular design of the ECO chillers mean multiple units can be connected to a single control interface, providing centralized control of up to 12 temperature-control circuits. A series of 60-ton units, for instance could deliver up to 720 tons of cooling. Processors can build system based on existing loading requirements and then easily expand to meet future needs.

Wide ambient operating conditions, from -20 to 125F (-29 to 52C) mean the ECO chillers can operate in all but the most extreme environments. An operating setpoint range from 20 to 80F (-6.6 to 26.6C) allows them to meet almost any process temperature requirement with +/- 2F accuracy.

Green Cool Technology

“The ECO name falls in line with other Conair heat-transfer products including EarthSmart™ label,” explains Jim Fisher, General Manager, Heat Transfer. “Among other energy-saving features, the new central chiller line offers instantaneous, continuous calculations performed to deliver increased efficiency under partial load, with automatic refrigeration pressure control. Variable-speed fan motors and dynamically controlled valves also ensure efficient operation at low noise levels and deliver increased temperature stability under varying load and condenser inlet temperatures. We call this Green Cool technology.”

PLC Control

The new Conair chillers come equipped as standard with the same PLC control and a 7-inch color touch screen HMI used on other Conair chillers, making operator training and maintenance much easier. The clear, simple-to-understand digital display shows all significant pressures and temperatures, as well as compressor/pump/fan running hours, and performance trend charts for key operating parameters such as process fluid temperatures. The control also include Modbus RTU or TCP/IP communications as standard with other communication protocols available optionally. It is fully compatible with the SmartServices™ platform — Conair’s cloud-based Industry 4.0 solution for auxiliary equipment monitoring, management, and analysis.

Other Standard Features

Chiller evaporators use a high-efficiency brazed plate heat-exchanger, and pump packages for high and low pressure can be provided as well. This kind of construction ensures maximum performance, long life, and an enhanced level of protection from harsh process conditions. Micro-channel aluminum condensers are energy efficient and compact, use less refrigerant, and withstand high-pressure spray for easy cleaning. Compressor protection is ensured by start-to-start anti-recycle control logic that limits cycling under low-load operating conditions, extending compressor life. The 24-volt DC power supply ensures dependable control circuit power and isolates the control circuit from static interference to ensure stable and precise operation.

Besides offering discrete packaged chiller units, Conair is also well-known for its unparalleled systems design and installation capabilities, making use of a full-time in-house installation crew. ECO chiller also come with Conair’s exclusive Uptime Guarantee and are supported by the industry’s largest and most experience team of part and service specialists.

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New Wireless RFID Line-Proofing Technology Guides Resin Selection and Purging Using Color-Change Indicators

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Conair’s new wireless RFID line-proofing technology uniquely simplifies and error-proofs resin distribution by translating source/destination connections from the conveying control and HMI into operator instructions guided by color-changing LEDs on the resin selection tabletop.  Other key features of this easy-to-use system include an LED-guided line purging option and full compatibility with Conair’s evolving Wave Conveying™ technology.

The new RFID line proofing system works with Conair’s recently introduced SmartFLX™ conveying control and an RFID-capable Resin Selection System (RSS) table. Each material port on the modified RSS table connects, via a fantail assembly, to a specific resin supply and is associated with an RFID antenna that is protected from damage beneath the RSS tabletop. All resin sources, along with their RSS ports and unique RFID antenna addresses, are tracked in the material source/destination database in the SmartFLX control.

Above the RSS table, the flex tubes to destination receivers are equipped with steel connection handles that contain and protect uniquely coded RFID chips, whose addresses are associated with destination receivers and stored in the SmartFLX database. Wireless signals between the flex-tube RFID chip and the antenna at each RSS port are used by the SmartFLX control to proof each connection.

Light-guided material selection prevents operator errors

When an operator initiates a material change using the RSS table, the SmartFLX control consults the material/source/destination database to identify one or more RSS port(s) linked to the correct resin source, as well as one or more flex tube(s) linked to the desired destination. Then, as these correct connection(s) are displayed on the HMI screen, the control translates them into light-guided instructions using LEDs embedded in the surface of the RSS table.

A correct flex tube (destination) is indicated by a flashing yellow LED, indicating that it should be unplugged from its current position and moved to a new RSS port (source) identified by a flashing blue LED. To make the connection, the operator moves the flex tube end to the indicated RSS port, then connects the tube into the port, aligning the tube’s RFID-equipped handle with the tabletop slot next to the port. Inserting the tube handle into this slot aligns its RFID chip with the port’s RFID antenna, enabling the SmartFLX control to proof the connection. The tabletop LED flashes green to indicate a good connection, after which the SmartFLX control unlocks the destination receiver and initiates the conveying cycle.

Should an operator attempt to connect either the wrong tube or port, the tabletop LED at that port flashes red, indicating an error, while the LED for the correct port continues to flash blue until the correct tube/port connection is made. For added reference, the SmartFLX HMI continues to display the correct tube/port combinations as well, using numbers that correspond to the markings on flex tube handles and RSS port positions.

“Clean Cycle” Purging Process Eliminates Resin Contamination Risk

Conveying systems often have a combination of non-purged and purged lines. Lines that are not automatically purged (e.g., cleaned with an air-only purge cycle that flushes all remaining resin to the receiver) may leave behind some resin that can be picked up, contaminating the resin in the next conveying cycle. Many line-proofing systems rely on operators to recognize this risk and perform a manual line purge when needed. But if busy operators forget, resin contamination can occur.

To error-proof the cleaning of non-purged lines and eliminate any resin contamination risk, Conair’s RFID line proofing system introduces “Clean Cycle.” This process combines a filtered purge-air source/port on the RSS table with color-coded LED indicators that guide operators through the correct purging sequence. It is managed by the SmartFLX control, which knows the purge status of each source and automatically adds the Clean Cycle process whenever resin is conveyed from a non-purged source.

Here’s how the Clean Cycle process works:  As soon as an operator completes a material conveying cycle from a non-purged source, the LED at that RSS port switches from flashing green to flashing yellow – indicating that the flex tube needs to be moved – while the LED for the Clean Cycle port flashes blue. When the flex tube is connected to the Clean Cycle port, the purging connection is proofed, its LED flashes green, the destination receiver is unlocked, and the line is completely purged – any remaining resin is pushed through to the receiver.

Completion of each Clean Cycle process is managed and validated by the SmartFLX control and recorded for traceability in the SmartFLX event log. Even in the event of a long delay or an operator change, the yellow and blue LEDs associated with the Clean Cycle process remain lit until the purge operation is completed. Only then can normal resin selection and conveying resume.

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