Operating Results for ACSI`s BrainWave® Model
Transcription
Operating Results for ACSI`s BrainWave® Model
Operating Results for ACSI’s BrainWave® Model Based Control Prove Successful at Several Leading Float Glass Manufacturers ACSI engineers have successfully integrated Model Based Control technology into multiple leading float glass plants. Previously, one of the above mentioned leading float glass manufacturers had been using standard PID loops to control glass level and canal temperature. By incorporating BrainWave® model based control into the existing Melter system, ACSI was able to provide the customer with optimal results that exceeded expectations. BrainWave® technology combines adaptive modeling and predictive control to obtain the best possible results in the least amount of time. Problems with current solution: The customer’s glass level control, a simple PID loop, was being compromised due to oversized batch logs not melting properly and disturbed convection from the oversized logs cooling the glass beneath the batch blanket. These problems were causing process performance to deteriorate in the forms of poor fuel efficiency and off-quality glass. The cascaded closed control loop, controlling the Canal temperature, required frequent tuning, produced sluggish response time, and caused an unacceptable variability of the canal temperature. Results: ACSI’s BrainWave® Model Based Control solution provided the customer with measurable advantages both economically and operational. Benefits/Customer Results ♦ 2.7% reduction of fuel consumption without compromising quality ♦ ♦ Check out our updated web site at www.acsitoledo.com. 30% reduction of defect density Added an additional 10 tons per day without compromising quality ♦ 50% reduction on error from setpoint in glass level ♦ Canal temperature variability was reduced by 72% ♦ Melter Temperature variability was reduced by 67% Volume 2 Issue 2 Meet Diana Davis What do you do at ACSI: I am an administrative assistant . Started with ACSI: February 5th, 2007 Hometown: Columbus, OH Background: The Ohio State University; BA in Medical Dietetics Favorite Movies: Father of the Bride ....it always makes me laugh yet touches and warms the heart. Favorite Summer Time Activity: Tennis and Gardening Interests: Family, Eating and Tennis Best thing about working at ACSI: Definitely the people....everyone is truly nice and great to work with! everyday! Meet Derek Kieffer What do you do at ACSI: Purchasing and shipping/receiving Started with ACSI: January, 1996 Hometown: Sylvania, Ohio Background: Kent State - Marketing Favorite Movies: Indiana Jones and Gladiator Favorite Summer Time Activities: Boating and Running Interests: My kids, Steelers football, and working on my house Best thing about working at ACSI: You get to dress up really nice for work! Temperature Control for Fiberglass Forehearths Previous forehearth control systems have relied solely on PID feedback control for glass conditioning to the bushing. ACSI has optimized this control by using advanced model based control (BrainWave®) to achieve exceptional stability and control right at the point of entry to the bushing. The models use both feedback and feed forward strategies. Customers who have applied the ACSI solution have realized significant benefits including improved production efficiency and excellent temperature stability. The solution has been applied to both new and older forehearths using existing control systems with excellent results. Eight days of forehearth zone control before applying ACSI optimization. Eight days of forehearth zone control after applying ACSI optimization. Volume 2 Issue 2 c Temperature Control for Fiberglass Forehearths (cont.) FEATURES • Model Based Control of Zone temperatures (BrainWave®) • Feed forward and Feedback control • The model learns and adapts to process changes BENEFITS • Improved Temperature Stability • Disturbance Rejection • Increased Production • Reduced Breakage ACTUAL CUSTOMER RESULTS 200% reduction in temperature variation 50% less time to achieve stability over PID 2% improvement in Pack 20% reduction of Bushing breaks per hour Application Strategy ACSI brings an additional level of control to the existing melter, forehearth, and bushings control system using BrainWave® Model-based control software. The ACSI Model Based Control System has the ability to track process dynamics, predict actions, and drive temperature quickly to setpoint while avoiding overshoot making Model Based Control more efficient than traditional PID. The controller learns process transfer function, adapts to process changes, understands dead time and never requires tuning. With tighter control, deviations from setpoint are greatly reduced which in turn leads to increased product consistency and quality. Adaptive control minimizes job change time by reacting quickly to stabilize temperature variations. Volume 2 Issue 2 ACSI 2008 Event Calendar ACSI Europe’s Art Lawrence at Glassman America in Monterrey, Mexico May 7-8 2008 Glassman America Monterrey, Mexico October 21-25 2008 Glasstec Düsseldorf, Germany November 3-4 Glass Problems Conference Columbus, Ohio ACSI looks forward to seeing you at our remaining 2008 trade shows! News from ACSI Europe (by Arthur Lawrence) ACSI Europe continues to expand business worldwide ACSI Europe is gaining new customers as the worldwide demand for glass continues to grow. Projects now reaching “commissioning phase” are taking place this summer and new customer projects will be undertaken this year. These include commissioning of an Adaptive Model Based Control system for a lighting application in Hungary, a melter and forehearth system in the UK, and a booster system in the Netherlands. New customer projects include a container glass melter and forehearth system for Russia through a UK furnace contractor and two new container glass furnace and forehearth systems through a German furnace contractor. In our non glass business, Rob Haydon will commission two new projects for bar coding, tracking, and packing of snack bars in the UK. Volume 2 Issue 2 ACSI USA 8750 Resource Park Drive Sylvania, OH 43560 Phone: 419-843-4820 Fax: 419-843-4821 Email:[email protected] ACSI Europe Ltd. Grove Business Center Boston House Grove Technology Park Wantage Oxon OX12 9FF Phone: 011.44.123.5227.274 Email: [email protected] improving performance through advanced control solutions This Newsletter is published by ACSI 4 times per year. All rights reserved. Editor: Katherine Wright, 419.843.4820 [email protected]. To unsubscribe, send request to the Editor. Volume 2 Issue 2