In 2020, the company Algor srl created, for DKC Europe, an automation system on the line for the surface treatment of industrial cabinets' production of the RamBlock line, with several objectives: to improve production quality through an automation and data remote control system, to make the use of chemicals in the process more efficient, to achieve optimal environmental sustainability of the painting activity.
Activities-Aliaxis-Italy
Crucial was the application of FIP-FLS instrumentation, which supported the project with the generation of continuous, reliable and robust monitoring of the fundamental parameters, to be sure at all times of the correct plant condition necessary to control the production cycle.
The parameters monitored are pH and conductivity, by means of probes installed in line, to maximize the reactivity of the feedback on the hydraulic and immersion systems through the punctual control of the chemical specificities of the baths in the surface pre-treatment tanks.
Added to this was the use of systems for monitoring the flow rate: in this case, the use of insertion technology was opted for, which minimizes the impact on the plant engineering and limits the need for prior planning of the installation. This provides the opportunity to implement the solution according to the plant logic highlighted in progress, even after assembly.
The project leader, Dr. Gnecco, says of FIP-FLS' products: "We needed simple and reliable instrumentation to carry out a complex and ambitious project. FIP has supported us in the best possible way in choosing the best instrumental set-up, facilitating this basic but fundamental part and letting us focus on issues related to the management architecture, signal processing and data delivery.
The electronic components for the management of the sensors (editor's note: pH, conductivity, flow) are easy to use, equipped with a simple and intuitive interface capable of guiding even the less experienced operator in calibration and setting procedures. Last but not least, we have benefited from the application of Bluetooth® low energy technology on the rotor flow meter (ed. F3.00.W.13); Given the plant constraints, it has allowed us to avoid expensive and inconvenient wiring, reducing installation times to hydraulic preparation only. This tool offers stable and diagnosed communication and a remarkable immunity to electromagnetic disturbances, so its choice immediately freed us from any worries."
Given the positive results achieved and shared with the customer, this automation project is continuing with the involvement of other industrial sites owned by the DKC group, in the desire to replicate the significant increases in efficiency and stability and control of the production process.
"We are very satisfied with this project" explains Eng. Michele Oberti, Head of the Production Unit Department, "The results went even beyond the already ambitious initial expectations. Our RamBlock line of metal carpentry now benefits from higher and more consistent quality standards of painting , thanks to the immediate intervention of the system in the event of process anomalies. The simplicity and concreteness of the system are two characteristics that have led us to extend the project to other production sites, to the benefit of operational management and quality for the end customer."
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