Automation of preparation at Wienerberger plant in Malsch

Thermoplan masters myriad automation challenges

Thermoplan GmbH has been solving people‘s automation and process-engineering problems for 3 decades now.

Over the years, all conceivable parts and components of brickworks have been addressed and the relevant challenges mastered with Thermoplan‘s state-of-the-art control technology. Solutions have been found for slow processes like drying and firing as well as for projects involving very fast processes and elaborate axis controls.

In such projects, either a new low-voltage power section is supplied or the existing one supplanted, or the control system is replaced or reprogrammed. In recent years, Thermoplan‘s service spectrum has been expanded to include the programming and supply of robots. Such solutions have been provided of late for the following areas:

› kiln/dryer

› kiln/dryer car handling system

› robot integration/replacement

› setting station

› unloading station

› preparation

› de-airing extrusion unit

› wet-end equipment

› turntable press (incl. hydraulic components)

› weighing/mixing systems

› pneumatic conveying equipment

In addition to this wide range of control engineering/automation products and services, Thermoplan GmbH also has to offer a dedicated Web service-based, freely expandable control system with multi-user support. Each workstation, equipped with its own network access and browser, becomes an operator control station (incl. tablet PC or smartphone).

Preparation plant, Wienerberger GmbH, Malsch facility

One recent example of successful automation is the preparation control system that Thermoplan implemented for Wienerberger GmbH in Malsch after a fire last year. Due to time pressure, the project encompassed existing, used and new components, a new control system and all-new cabling/wiring.

One of the main reasons why Wienerberger called on Thermoplan to implement the project was that the Malsch facility already possessed the company‘s software structure, which has two features of prime importance: All major plant control modules have LAD/FBD programming. All I/O addresses and function flags are directly implemented (i.e., all I/O/Fs are implemented directly in the software and therefore readily locatable via step-7 functions). The software is designed for easy integration or alteration at some later point in time.

While dispensing with complex prefabricated modules for control system construction does involve a lot of extra work for developing the software, it adds significantly to the legibility of the programme and makes it much easier for the local maintenance people to adjust to altered circumstances.

This software concept also attaches priority to executing the programme and process intelligence, as well as any existing article management, completely in SPC for any and all intelligent peripheral equipment with its own controls – e.g., frequency inverters, robots, etc. This makes it easier to exchange components and to manage the overall software package at some later date. Hence, those responsible for system maintenance can concentrate on step-7 competence instead of learning to handle additional new software packages.

In keeping with the software‘s maintenance-friendly, future-proof structure, only standard components from reputable producers, such as Siemens, Phoenix, Danfoss, SEW (or as requested by the customer) are used for the machine control scope, and all operating functions are realized via WinCC (flex). This, too, ensures that the maintenance department will be able to properly maintain and take good care of the plant.

The Malsch project was planned in close cooperation with the local maintenance team and completely implemented, including all cabling/wiring, by in-house personnel.

The fuseless design of the control cabinets (with the exception of the large frequency inverters) and the clear-cut structure of the cubicles themselves are state of the art. The operator-control concept based on local operator-control stations was also coordinated with the plant.

Implementation of the project, including the unique fact of a double-shaft mixer perched on the tempering silos from 200 m away (with all the requisite cabling) took roughly seven weeks for the electrical scope and another two weeks or so for commissioning the plant and running it up to 100% output.

x

Related articles:

Issue 05/2012

Thermoplan converts wet side and setting station at Wienerberger plants in Malsch and Bad Neustadt

Winter before last (2010/2011), the setting installation at ­Wienerberger‘s Malsch facility was completely rebuilt, and a total of three unloaders/hand­over grabs were replaced with a robot. The...

more
Issue 11/2013 Wienerberger GmbH

Malsch Brickworks back in production

At the beginning of Sep­-   tember, the brick presses at Wienerberger’s Malsch plant in Baden-Württemberg started up again. Production of all Poroton clay block sizes will be successively resumed....

more
Issue 12/2010

Cleia brings together Ceric Systeme and Ceric Automation

Ceric Systeme and Ceric Automation have joined forces to form a new company under the name Cleia. The company based in Nolay, an industrial centre around 250 km south of Paris, plans to further...

more
Issue 6/2012

New clay preparation, souring and shaping line at Wienerberger’s Rumst facility

Ceratec successfully delivered a new clay preparation line, a clay souring plant and a shaping/extrusion line to Wienerberger’s Porotherm site located at Rumst, Belgium. This new plant enables...

more
Issue 03/2010

Thermoplan kiln controls for a Ceric kiln at Creaton AG in Roggden

For over ten years a dryer control system and an operational data logging system from Thermoplan have already been in operation at the Roggden plant. In addition, systems to control the dimensional...

more