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