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CompuWeigh Automation Capabilities Summary CompuWeigh’s automation capabilities range from providing simple start/stop control through our scale controllers to fully automated multi-scale ship/receive or process control, even controlling an entire facility from one screen. The integration of our GMS data management and scale control system with our Automation System means that all information related to the movement of materials through the facility is immediately available – to operators, to supervisors, and to the accounting system. Our customers have found that working with CompuWeigh allows facilities to dramatically increase profits right away. Throughput is increased through improved efficiency (for example, allowing a manager to instantly analyze commodity grades and blend across a number of bins) and by eliminating costly operational errors like mixing commodities. For example, one customer using the Inventory module reports that his "daily reconciliation was cut from over 2 hours to 15 minutes" and that the end of the month reporting time was cut from 2 days to "done before 8 a.m." .
Unique ability CompuWeigh is the only company with the ability to combine powerful, NTEP-approved scale data management capabilities (like ticket printing, accounting interface, report writing, grading, blending, and inventory for both bulkweighing and platform scales) with automated control functions.
Definition of Terms used here NTEP – National Type Evaluation Program. -- A program of cooperation between the National Conference of Weights & Measures (NCWM), National Institute for Standards and Technology (NIST), State Weights & Measures officials, and the private sector for determining conformance of weighing with the provisions of NIST Handbook 44. Currently, more than 30 states require NTEP approval for scale equipment to be used in "legal for trade" applications. All CompuWeigh hardware and software, including GMS, is NTEP approved. PLC – Programmable Logic Controller. A device which performs input/output and control logic functions, and communicates with other devices in industrial automation applications. GMS – GMS (Grain Management System®, but can be used for any industry, not just grain) is an NTEP-approved legal-for-trade scale data management program from CompuWeigh that gives operators a simple means to enter data related to scale operations, and gives management the ability to track every bit of scale data. It is a critical building block on the road toward facility automation. MMI – Man-Machine Interface, more recently known as HMI (Human-Machine Interface). Graphical package that allows operator to see an overview of an entire facility or part of a facility at a glance. Operator is able to start and stop equipment, monitor alarms, run maintenance reports, see trends, and link to CompuWeigh’s GMS software from one workstation. A few of the more popular MMI packages are produced by Wonderware (InTouch), Intellution (FIX), and Allen-Bradley (RSView).
What’s CompuWeigh’s experience in automation? Good question. There are a number of systems on the market able to handle data, and an even larger number of automation experts writing software to handle process control. Only CompuWeigh combines these two skills. Here are a few recent examples:
Automation starts with GMS The automation journey starts with GMS, because before complete facility automation is achieved, the data must be understood and well managed. To an elevator or manufacturing facility, scale data is critical. Once the data is under control, then facility automation can move ahead – tying in alarms, controls, indicators, PLC’s, more capability with GMS, and other features. GMS is written from an operations standpoint, for operators – not from an accounting standpoint – meaning that we wrote it with "simple to use" at the forefront. For example, although GMS is a Windows 95 / NT product, the operator is never required to use a mouse. The system is modular, so options like automatic grading, blending, inventory, reporting, bar coding, and of course – automation – can be added at any time.
Building block approach allows customers to "pay as they grow" This approach lets our customers build into facility automation as their time and budgets allow. End users can start with a simple GMS, then add modules as time and budgets permit. When they’re ready to get into automation using an MMI (Man-Machine Interface) package, we can build that in right on top of GMS. A facility can add an MMI system to improve process control, while operators continue to use all the same function keys they’re accustomed to on the data entry side, meaning that retraining is kept to an absolute minimum. Anyone who’s done MMI work is familiar with the data handling limitations of the major MMI packages. The combination finally allows operators and plant managers to use GMS to enter and manage the data related to receiving and shipping while the MMI package handles the process control. Finally, a facility can enjoy the best of both worlds.
Moving toward facility automation For example, in a typical receiving operation, operators using the CompuWeigh Automation system simply select destination bin numbers from drop-down lists (in GMS). From there, the MMI system automatically selects the product flow path, places components like turnheads and basket valves in the proper position, then starts the proper handling equipment in the proper order. In another example, easy operator control over proportional bin bottom gates allows a grain facility to more accurately blend products and therefore maximize profits. Using the CompuWeigh blending module to add just 1 cent per bushel (quite realistic) to an elevator’s existing profits can mean an extra $20,000 or more profit per month! Complete equipment interlocking is maintained during all phases of operation, including equipment startup and shutdown. Purge timers can be interlocked to ensure that the product has cleared components before changing state or position. From a safety standpoint, the CompuWeigh Automation System can monitor equipment for proper operation. Some of the equipment components that can be monitored include:
Automation designed with operators in mind CompuWeigh’s automation alarm functions are programmed on the principle of "exception reporting." This means that if everything is OK, we simply display the status as is, but do not draw particular attention to the status. However, the MMI package is constantly monitoring the status of all I/O points. If a component moves into an alarm condition (perhaps a bearing temperature climbs outside of normal limits, or a high-level switch in a bin is tripped), we make that immediately clear to the operator. We’ll display a large box on the screen (sound horns, flash strobe lights; depends on customer’s specs) which will insist the operator acknowledge the alarm and fix whatever’s causing it. For analog output components several level thresholds can be set up. The operator will be warned once a component’s value starts to move outside its normal operating limits (for example, the bearing temperature climbs just above the "notify" limit). If a potentially hazardous condition occurs (the bearing temperature climbs above the "shut down" limit) the automation system can immediately shut down the suspect component. With a complete monitoring system in place, insurance premiums are often reduced.
Other features available in CompuWeigh’s Automation System include:
We’ll work with you CompuWeigh is always willing to "plug in" capability wherever it’s needed. For example, we can do PLC programming, or we can leave that up to you or to a local electrical contractor. Or you might have engineers on your staff who are skilled at MMI. Fine. We can provide "scale strips" on an otherwise blank MMI screen. Your engineers don’t have to worry about scale control, high-speed communication protocols, legal-for-trade approvals, or government regulations on the scale side – they can move ahead adding the graphics and control work. Of course, we can always do the whole job from PLC programming right through MMI implementation if you’re interested in "one stop shopping."
What’s Next? Since no two facilities are identical, each potential project must be evaluated independently. Whether the facility is new or a retrofit of the current control system, CompuWeigh can provide the necessary technology to improve your process and/or reduce the manpower required to operate the facility. Here are some questions to see if automation is right for your facility.
Automation questions for end user
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For more information, contact:
Post Office Box 23602
Louisiana: 1-504-733-4871; 1-504-734-1880 FAX |
