Special Line Solution with System

The automation company BSG which is well-established in the polymer sector mainly produces custom-made automation solutions for extrusion lines. Beside this core business, moreover, also special lines of the polymer industry are automated. So, the company Krah AG only uses the control and operating system ONEoperate developed by BSG.

The operating terminal of the ONEoperate system is optimised on the requirements of the windable pipe production system. The German technology supplier Krah AG designs and produces special lines for the production of PE and PP pipes with a large-scale diameter of up to 4000 millimeters. In close collaboration of both companies, the ONEoperate system from BSG was modified according to the requirements of these special lines. It consists of the control of the complete line which is based on the Helicon Extrusion Principle, a direct extrusion procedure.

Sea outfall pipe with a external diameter of 2000 millimeters. Here, with a main and a co-extruder via a die head, the plastic is applied on a pre-heated steel drum double-ply. Additionally, via a second die head, a covered support pipe is winded on the primary layer. This forms the pipe profile and allows a high stiffness at minimal possible material usage. The plastic and the support pipe are spirally applied on the steel drum. For this, the steel drum is positioned on a moveable production station and rotates via driven rolls in the necessary speed around its own axis. During the winding process, the production station is passed over the extrusion unit via a rail line in order to guarantee that the PE layer is evenly dispersed. The application of a second layer is possible by moving the carriage backwards. Flexibility is a big advantage of this production process. All diameters from 300 – 4000 millimeters can be produced with one line. The changeover time takes 15 minutes on average.

The automation consists of the transport of the raw material, the gravimetric dosage, the extruder and co-extruder and the moveable production station. The specific raw material for the corresponding pipe is software controlled mixed via the gravimetric dosage and molten in the extrusion unit. The corresponding control recipes are chosen via the central control panel. Additional set value requirements of involved aggregates are also defined via this panel. By ONEoperate system, the operator is logically guided through the complete start sequence. For high quality of the pipe, a constant draw-off speed is very important.  So, the wheels for the rotation of the production tool and the horizontal movement of the production pivot mounting are driven by a specially synchronised servo convertor.  With this, a continuous movement and draw-off speed are reached. This is essential for the constant wall thickness of the produced pipe. In order to support the operator during production perfectly and intuitively, the operating terminal is designed according to the special requirements of the line. „The step-by-step user guidance and the flexible adaptation of the operator terminal to special requirements makes the ONEoperate system so valueable for our lines “ says Sven Jürgens, Technical Manager of Krah AG.

A high investment security in the automation sector is guaranteed by using hardware of well-known European manufacturers. Possibilities of an integration in the infrastructure of a company is given by bus systems and network interfaces in the line. 

For quick and unbureaucratic support in an emergency situation, in all BSG lines, a teleservice is integrated. By a 24 hours hotline, in an emergency situation, a BSG-service engineer is contacted. The engineer professionally helps via the teleservice connection and if necessary, additional action will be taken.