mixing piloting and control systems

Mixing piloting and control systems : CT Datentechnik

Consits for us of the right mix of experience and new ideas. Since 20 years CT Datentechnik is successful in the development of software for the control of batch processes in the rubber and brake pad industry. A dynamic team is constantly engaged with the development and improvement of the products.

Our know-how allows a precise functional analysis and to modernize existing lines (SOW 1000 of Chronos) or new and to change the obsolete automatic components.

The automatic control of the production process offers the following advantages:
•    quality assurance, from raw materials to final products
•    improvement for quality audits
•    increased flexibility in order processing
•    smoothing of the production sequences by means of time planning and balancing of available resources
•    increased productivity through the implementation of time planning
•    rationalization through avoidance of production rejects and losses
•    reduction of verification expenses due to controlled process flows

In addition to the quality assured production process the software is also responsible for administrative tasks:
•    master data management (material lists, material data, work flows etc.)
•    order management (e.g. calculation of material needs)
•    storage volume management (material consumption, minimum stock quantity control)

Technical solutions of rubber mixing process optimisation in real-time MixCont
Logiciel MixCont - 

Mixcont is a set of intelligent tools for the mixing room, including intelligent, adaptive, self-learning control system for rubber mixers and a wide range of supporting tools like statistical tools(including Mooney estimation at discharge moment), failure detection tools, laboratory management tools(LIMS), labour & machinery utilization tools . MixCont was introduced at the market in 1997 in Sweden. Since than it has been installed and successfully operates at a number of factories producing rubber compounds nearly for all the branches of rubber industry. Over the years the system has been controlling mixing of compounds based on tens thousands different formulations, improving quality of the most of the compounds and providing essential time and energy savings for the compounds’ manufactures. Further more usage of MixCont support tools additionally improves productivity and quality.

How it works
Mixcont system uses internal mixer with installed sensors and Mixcont data acquisition, processing and analysing units as device testing quality of the compounds while the mixing is running. The sensors and the data acquisition units provide the system with the values of signals, like the motor current, rotor speed, ram position (continuous signal), measurement of thermocouple and ram pressure. Mixcont data processing and analysing tools process, analyse and interpret the gathered data providing Mixcont control system with online information related to the mixing process. The information includes evaluation of changes in dispersion, distribution and plasticity of the batch during the mixing. It is taken as the basis for Mixcont control system to perform on-line automatic optimization of mixing process. The goal of the optimisation is to provide required dispersion, distribution and plasticity for every batch and within minimum possible mixing time. Another data used by Mixcont control system is also collected, processed and analysed with Mixcont tools. It is:
1.    Intelligence gathered during the mixing of the previous batches
2.    Process integral statistical data
3.    Detected state of the mixing equipment
4.    etc.
Results of Mixcont on-line automatic optimisation of mixing process are considerable improvement in final properties of rubber compounds and essential time and energy savings at the same time.