Flumasys as a supplier of the complete ABB range of drives for the plastics industry
Expansion of the portfolio with ABB products - drives division
With our specialisation in advanced industrial technologies, we help customers improve the efficiency of their processes. In 2023, we have expanded our portfolio to include ABB products, Drives Division. These include low-voltage electric motors, frequency converters, control and safety systems for drive control, which find applications in the plastics industry. Our priority is to provide comprehensive and reliable solutions from a single source, supported by an experienced team of experts.
Cutting-edge technology tailored to the plastics industry
The plastics industry is characterized by high demands for precision, energy efficiency and reliability in production processes. ABB products distributed by Flumasys are designed to meet even the most demanding needs:
What does Flumasys offer its customers in the plastics industry? They can choose from a comprehensive range of standard products, but Flumasys, in cooperation with ABB, has also developed packages designed to meet the specific requirements of tasks in the plastics industry. The complete solutions cover automation and drives from control system to motor output shaft, from speed and torque control to position and motion control, from design work to commissioning and service.
What benefits do customers get if they choose to take advantage of ABB's offer?
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thanks to efficient electric motors, optimised control of individual operating variables and the entire control process, customers will achieve excellent energy efficiency
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a unified engineering environment and software supporting commissioning and service simplifies the work of operating and service technicians
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thanks to the choice of many communication interfaces, machines and equipment equipped with ABB technology can communicate within the company's control and information system and remote diagnostics and monitoring can be easily implemented
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customers can use both centralised and decentralised control system architectures to develop solutions to suit their exact needs, or adapt them flexibly in the future based on changing requirements, always at a good value for money
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customers can benefit from ABB's expertise and extensive experience in the application of electric motors, drives, programmable automation, control and communication systems and robots
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as a global company, ABB guarantees its customers local support wherever they are in the world, whether it is consultation during the design phase, assistance during commissioning or service provision.
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| Fig. 1. Schematic diagram of the plastic machine (>>> - remote control, DTC - direct torque control, η - power optimization, ΔT - adaptive temperature control, Δp - pressure control, M - position control, W - winding function) | |
Extrusion presses
Extrusion presses are manufactured in many types and sizes. Therefore, they use a variety of DC and AC drives. ABB offers standard asynchronous electric motors, servo motors, DC motors, permanent magnet motors and synchronous reluctance motors to meet any extrusion press drive requirements. The control of the drives guarantees not only the control function but also optimal operation in terms of electricity consumption.
Modern drives have dynamic torque limitation on the extrusion press screw, even without speed feedback, and even for synchronous motors (with or without permanent magnets). The drives can also incorporate a decentralised PID controller to regulate the pressure at the press output; another option is to implement the controller as part of a central control system.
Another important part of the extrusion press is the multi-stage heater. For this, ABB offers adaptive thermostats that allow precise and energy-efficient temperature control in the individual heating stages. The control module with autotuning function, which is part of the AC500 PLC, can be used to set the desired values and control parameters of the individual thermostats.
Dosing pump
The task of the dosing pump is to ensure a constant supply of molten plastic to the extrusion press nozzle. The flow rate and outlet pressure are regulated by the speed control of this gear pump.
Refrigeration and elongating machines
In film production, the plastic is extruded onto the cylinder of the cooling machine. To guarantee the correct thickness and surface quality of the film, it is necessary to maintain the correct belt tension. Even more complex is the production of long films, which are reheated to the required temperature behind the cooling roller, clamped and lengthened, usually in two stages, first transversally and then longitudinally. The strength of the foil increases in the direction of elongation as it is elongated. ABB drives with position and motion control functions can be used to regulate the tension of the film belt in the cooling machine and to drive the drift chains of the lengthening machine.
Winding machines
The finished film is wound on a drum. When winding, it is necessary to guarantee a constant tension in the wound strip. This leads to the need for a torque-controlled drive. In addition, the drive must be able to accommodate different reel diameters. This can be achieved by combining the drive with a PLC or by using an ABB drive with software specifically designed for winding and rewinding machines. In addition to adjusting the roller diameter, the software can also compensate for the effects of friction and moment of inertia and detect belt breakage.
Follow-up processing
Similar control requirements apply to film follow-up machines: printing, slitting, perforating, etc. The whole spectrum of drive tasks is involved, from speed control to position control.
Both centralized and decentralized position control can be realized by the AC500 control system. A frequency converter with position control functions or the position control modules MotiFlex e180, NextMove e100, MicroFlex e100, MicroFlex e150 and MicroFlex e190 can also be used. Different types of position sensors are supported.
Security
The advantage of supplying ABB is that, in addition to controlling the drives and regulating temperature and pressure, the company can also take care of the safety of the machines, both through safety PLCs and by using safety functions that can be a direct part of the drive control modules.
Direct torque control
In plastics machinery, there are often tasks where a quick response to changes in drive load must be ensured. The direct torque control method is particularly suitable for these applications and is used in asynchronous motors, permanent magnet servomotors and synchronous reluctance motors. This method, abbreviated as DTC (Direct Torque Control), allows speed and torque to be controlled without sensors in the feedback loop.
The benefit of direct torque control is the high accuracy of torque control from zero speed. Since no feedback sensors are required, installation is simpler and the overall installation cost is lower. Direct torque control allows the motor to be operated in the area of best efficiency, thus reducing electricity consumption.
Simple programming
ABB has developed Control Builder Plus, a unified engineering environment that allows you to program PLCs and drives, create operator panel applications, set communication bus parameters and implement web services. In a unified environment, engineers have easy-to-use, intuitive tools for programming, configuration, parameter setting, diagnostics and service, applicable to almost any automation project, including plastics machinery.
Overview of automation tools for plastics machinery
The AC500 PLC series can be recommended for the control and management of plastic machines. Their advantage is their great flexibility, allowing them to be adapted to the exact requirements of the task at hand with regard to the required computing power, the range of functions required, the number and type of inputs and outputs and the communication interface. ABB also offers a wide range of operator panels.
In the plastics industry, ABB's low-voltage AC and DC drives, e.g. the ACS880 and ACS580 inverters for higher power outputs or the ACS380 for machine drives, find application. The range is complemented by modern DC inverters, such as the DCS880, suitable for new installations and for upgrading older machines and lines.
ABB offers an extensive range of electric motors of different principles, sizes and outputs in efficiency classes IE2, IE3, IE4 and IE5.
The AC500-S safety PLC and ABB Jokab Safety devices can be used to ensure the safety of machines and machinery.
If you would like more information or would like to consult on a specific project, please contact us at info@flumasys.cz or visit our website.
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Flumasys s.r.o.
Authorized distributor of Nordson, manufacturer of dosing systems, technologies for regeneration of industrial filtration in industrial automation
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