The Arburg host computer system ALS – a powerful information centre for plastics processing

This MES, which has been designed specifically for use in the production of plastic parts and components, provides the basis for efficient and transparent production and resource management. The tool continues to be developed on an ongoing basis. Its latest features include mobile ALS functions for resource-efficient paperless production.

The ALS supports secure documentation and central administration of machine data without manual intervention. Job progress, machine statuses, process parameters and alarm messages are captured online. A typical injection moulding plant running 20 machines can save approximately 1250 hours of working time per year using the ALS. In addition, the latest optimised and approved configuration data for the production process is available at all times, ready to be transferred directly to the machine at the start of a job. This is where smart manufacturing starts.

IIoT gateway for comprehensive networking

Networked injection moulding production requires machines to be interlinked in a manufacturing execution system (MES). All ALLROUNDER injection moulding machines feature "basic connectivity" as standard; i.e. they are equipped with an IIoT gateway so that they can be easily retrofitted with an OPC UA host computer or EUROMAP 77 interface. This means that data related to the process, quality or service can be provided to higher-level software tools and platforms (Fig. 1). Alongside the existing ALS hotline, Arburg has set up a dedicated support team for connectivity, a topic of major importance. The ALS features various interfaces to support the interlinking of injection moulding machines of all makes and brands. Furthermore, I/O modules (digital signals) can be used to interlink machines for which a data interface is not available or cannot be retrofitted without significant expense. There is also a flexible interface to the central ERP (enterprise resource planning) system.

Fig. 1: an IIoT gateway interlinks ALLROUNDERs with higher-level software tools and platforms.

Host computer system specifically for plastics processing

At the K international trade fair in back in 1986, Arburg first presented a fully automated production system with no manual set-up processes, consisting of several linked injection moulding machines, a concept that put the company way ahead of its time. Controlled by an early version of Arburg’s in-house ALS host computer system right from the start, the system has undergone continuous development ever since.

Today, the ALS provides comprehensive transparency right across production – from detailed production planning to process optimisation, taking in the acquisition of job, machine, configuration, process and quality data, and going beyond to analysis, documentation, tracking and even maintenance and repairs. Data can be exchanged both via a PPC/ERP interface and the arburgXworld customer portal (vertical integration) and across production equipment and locations (horizontal integration) (Fig. 2). This facilitates a direct flow of information from machine right through to material planning, purchasing and sales.

Fig. 2: acting as a central connector, the Arburg host computer system ALS provides a platform for online data exchange across production equipment and locations (horizontal integration) as well as with an ERP system and the arburgXworld customer portal (vertical integration).

A modular concept – equal to any task

In short, the host computer system provides the basis for maximising the efficiency of a machine fleet; it enables production workflows to be planned proactively and exactly to the minute before being monitored and documented. Machine statuses and up-to-date indicators for jobs, shifts or production quality are readily available; they can be queried and displayed on a PC or mobile device at any time. Machine utilisation, production deadlines, production volume, set-up and maintenance work, including personnel requirements, can be monitored at all times.

A multitude of modules and functions are available for the host computer system and can be combined flexibly. The starting point is provided by the "base" module, with a central database that can be upgraded at any time (Fig. 3). Modules are available for four higher-level tasks:

• Information centre
• Documentation and archiving
• Production and resource management
• Quality assurance

Fig. 3: the ALS "Energy Visualization" add-on module supports the assignment and visualisation of energy data on a job-specific basis.

The ALS is able to facilitate efficient organisation, networking and documentation in production, in addition to configuration data management and production data provision in real time including long-term archiving.

Calling up the machine status in the ALS produces a display including status data (operating modes, alarms, causes of errors), operating data (parts counter, program, mould and order information) and even process parameters (actual values from the injection moulding cycle). The production overview shows the very latest status in the machine hall. It includes production progress and indicators including overall equipment effectiveness (OEE), availability, efficiency and quality rate. The monitoring and recording of actual values enables deviations in the production process to be picked up easily. It also contributes to the improvement and validation of production quality.

Tablet instead of paper

The machine terminal with its mobile ALS functions provides a stepping stone to paperless manufacturing (Fig. 4). As well as significantly reducing paper consumption, using a tablet instead of paper also saves a huge amount of time and creates transparency: the status of a process and production process, as well as up-to-date indicators, can be displayed via the individual modules. Additional resources can be added easily, jobs can be loaded directly onto the machine without typing, maintenance can be carried out paperlessly and hidden capacities can be revealed. A universal connector for the OPC UA communication protocol also enables other types of machine to be integrated easily alongside injection moulding machines.

Fig. 4: more transparency, less paper: with the mobile ALS functions, all important information is available any time, anywhere.

Visualisation of energy data

Companies that are certified to ISO 50001 in particular have to meet strict requirements applying to the introduction, implementation, continuity and improvement of their energy management systems. Detailed and ongoing energy measurements that show exactly where and how much energy is being used and/or consumed in a production process are vital to achieving compliance with these requirements. The values recorded can be analysed in job-specific and product-specific reports. The "Energy Visualization" add-on module in the ALS supports the assignment and visualisation of energy data on a job-specific basis (Fig. 3).

Preventive maintenance

In addition to production planning and data analysis, dedicated data exchange also supports areas of production including storage, mould construction and maintenance. Set-up processes can be optimised, operational sequences can be made more efficient and preventive maintenance can be supported. The ALS takes account of the storage location and availability of moulds, including master mould, inserts and accessories. Thousands of injection moulds can be managed if this is required.

New features for more power and functionality

So that the ALS continues to meet its customers’ specific requirements, Arburg uses the valuable feedback and suggestions it receives all the time in the ongoing development of the system. Converting the server modules to 64 bits in 2021 massively increased the usable RAM in the ALS – up to a maximum of 16 exabytes, in theory. Or to put it in practical terms, users are able to work seamlessly with the powerful ALS even with a constant flow of high-volume data. The ongoing development of the ALS is currently focussing on new modules and functions, for example; work is also continuing apace on enhancing the connection between the ALS and the arburgXworld customer portal.