Product category:
Control systems, panels, HMIs, interfaces, screens
News Release from: Mitsubishi Electric Automation Systems | Subject: Programmable logic controller
Edited by the Manufacturingtalk Editorial
Team on 08 December 2005
System tests toilet pans five times
faster
Automated test station developed by toilet pan manufacturer is five times faster than the previous arrangement, allowing it to vacuum test all pans rather than only a sample few.
Automated test station developed by toilet pan manufacturer JSI Leaches in Stoke-on-Trent is five times faster than the previous arrangement, allowing it to vacuum test all pans rather than only a sample few The control system is based on a small PLC (programmable logic controller) which performs the basic sequencing of operations, and a HMI (human/machine interface) from which the operator controls the test
This article was originally published on Manufacturingtalk on 16 Nov 2005 at 8.00am (UK)
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The HMI is a relatively simple unit, an E100 from Mitsubishi Electric, but it gives the operator local autonomy to make adjustments to the testing times if required.
Primarily it highlights the pass/fail results to the operator, but it also automatically collates tests results and forwards them for preparation of production management reports.
The PLC performs all the automated functions and is also a Mitsubishi product.
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"We went with the FX controller for several reasons," explained David Clowes, who lead the development project.
"The main one is that we have plans to further enhance the testing process by installing a powerful control and analysis software package, probably one of Mitsubishi's MX4 programs.
We are largely standardised on Mitsubishi control equipment throughout all our plants, and the FX in particular is so ubiquitous as to be an industry standard in just about every industry".
Toilet pans are produced by moulding; then they are fired and finally glazed.
The test that Clowes and his colleagues have developed follows on from the glazing stage and is designed to weed out any pans that could leak once in use, either because the moulding is porous or because the glazing has cracked (which can easily occur in some impossible-to-see recess of the trap).
In the test station, the operator clamps and seals a blanking plate over the toilet bowl's top opening and connects a vacuum hose to the bottom outlet, then the PLC takes over for the automated testing.
Vacuum is drawn within the pan to a defined top pressure, with a pressure sensor alerting the PLC when the set point is reached.
The PLC than activates a solenoid valve to isolate the pump, which runs continuously as it serves several test stations simultaneously.
The vacuum pressure is monitored minutely for the next 30 seconds.
If it holds steady, the pan passes; if it falls below a second set point, it fails.
Because of the HMI's controllability, the operator can extend or rerun the test on any pan he feels may be a borderline case.
"This flexibility means we can utilise the operators' ntuition and experience, values that although impossible to measure are nevertheless invaluable in an operation such as ours," said Clowes.
"There are regular instances of operators saving our market reputation by knowing which pans to retest".
The principles of the test station have been proven and JSI Leaches is in the process of installing multiple stations in all five of its UK plants and also in its Bulgarian facilities.
A test used to take five minutes, but now it is down to less than one minute, allowing the company to test every pan it makes. Request a free brochure from Mitsubishi Electric Automation Systems ...
Clowes concluded: "When we bring the extra software on board we will be able to compare one batch with the next, one site against the others, log and analyse long term production data, spot trends and constantly improve productivity and quality.".
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