Davis-Standard: First Wireless System for Monitoring Extrusion Processes
Davis-Standard and Adaptive Instruments will demonstrate the plastic extrusion industry’s first wireless monitoring system during NPE 2003. The “Accutech” wireless technology from Adaptive Instruments provides processors with a cost-effective, stand-alone solution for monitoring variables such as melt temperature, pressure, screw rpm and motor load from remote or hard-to-access locations. Since the system is non-invasive and requires no wire installation, permits or licenses, it can also be used for process data collection or to test the viability of a new project. Davis-Standard is the first extrusion manufacturer to apply the new technology and will illustrate its advantages at booth #5107.
According to Angelo Firenze, Adaptive Instruments’ president and CEO, the Accutech system is an extension of core wireless technology that has been applied to industrial applications. “Wireless is a proven, enabling technology and it was only natural for it to evolve to the extrusion floor. Our system is unique in that it’s a fully functional and portable wireless package, ready to use out of the box. We understand the importance of reliable and secure transmissions in extrusion processing, so we addressed those issues by equipping the system with two-way communication. This provides a means of checks and balances to ensure accuracy and to self-diagnose potential problems. ”
The system has a monitoring range of up to 3,000 feet and is equipped with a fully-integrated sensor and battery-powered field transceivers; a base radio transceiver with RS232, RS485 (digital), Ethernet and/or 4-20mA (analog) output; software for data management and exception reporting; and full assimilation to legacy systems. The components are individually calibrated between -40° and +185°F and all instruments are FCC certified for license-free use. Advantages include low installation cost, system portability, unlimited access to processing data, multiple input capacities, a flexible base radio output, low power consumption with 5 year battery life, two-way signal integrity and off-site monitoring capability. Each base radio transceiver can communicate with as many as 250 field units per second.
“Ease of installation is one of the primary benefits of this technology. The stand-alone sensors can be attached to any device on a processing line for wire-free monitoring from the sensor to the read-out mechanism,” said Jim Duckworth, vice president of engineering at Adaptive Instruments. “Since our software enables off-site monitoring, it’s possible for a processor to access data or be alerted to alarm conditions from anywhere in the world using a web browser, including a PDA or cell phone.”
An example of a typical system overview includes a PC (Davis-Standard’s EPIC III™) communicating via RS485 using Modbus protocol to one or more base radios that transfer data wirelessly from field units. The software program uses a simple command and response protocol to communicate with the wireless units. The demonstration at Davis-Standard’s booth will involve three static
extruders and a running cast film line. Davis-Standard will have two EPIC’s, each with a base radio, communicating to field units monitoring melt pressure and melt temperature. For the running cast film line, multi-input field units will monitor pressure, temperature, screw rpm and motor amps.
Jim Murphy, a Davis-Standard business director, says the new technology is ideal for monitoring variables on large extrusion lines. “By eliminating hard wires, the Accutech system is an affordable and practical option for processors operating long, complex extrusion lines. The simplicity and versatility of the system set-up combined with its diagnostic capabilities make this an exciting development for the industry.”
For more information about the Accutech wireless monitoring system or Adaptive Instruments, visit www.adaptiveinstruments.com. Or contact Angelo Firenze at afirenze@adaptiveinstruments.com . For more information about Davis-Standard’s application of this technology, contact Tom Lewon at tlewon@davis-standard.com.