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The Challenge 

^{A Pyrex}_® glassware manufacturer desired to upgrade their 24x7 process monitoring on high-temperature production glass  presses. The original, proprietary, C-based system was built on obsolete technology and was difficult to maintain and  modify. Equipment deterioration and obsolescence dictated a change from the present system with enhanced features.  

The Solution: 

Data Science Automation (DSA) developed a contemporary system based on National Instruments (NI) LabVIEW, PXI and  DAQ to acquire digital and analog signals from  displacement sensors, pyrometers, etc. for event and  process monitoring, and to replicate the original GUI  to simplify the end user’s transition. An industrial  PXI solution was suitable to sustain the harsh, high temperature environment and 24-hour operation. In  addition to real-time analysis and display of process characteristics, the data is being collected for archival  to a networked Oracle database.

Figure 1

The PXI solution utilizes a mixture of analog and  digital inputs to monitor the glass press process and  compare the analyzed values to stored parameters for  several types of glassware. It is critical to the quality  of the glass for the operator to have immediate access  to the analyzed data for adjustment of the process if necessary (Figure 1). This is especially true during  change of production runs. Running outside of these  specified parameters will lead to possible loss of  product and delays in the production cycle. 

Since the operators are accustomed to viewing the results with the current system the new solution would have to present the  data in a similar manner. LabVIEW allowed DSA to develop front panel controls and indicators that closely resembled the  old systems but have all the built in features to design a useful user interface. 

The system permits selection from several existing job files (recipes) which specify target values, ranges, etc. for various  pieces of glassware. These recipes have been well established from the years of production of several different types of  glassware. Production rates will range from 20 to 50 parts per minute. Manufacturing new designs and storage of the new recipes is easily accomplished through a spreadsheet recipe interface.  

Several signals from the press are being acquired from sensors and event timing signals are exchanged with the PLC which is  controlling a hydraulic ram for pressing the molten glass into the glass molds. In addition to the parameters being  displayed to the operator in the control  room, critical values such as mold  temperatures, ram velocity and event  timing need to be displayed for the  operators directly by the glass press.  This is accomplished by the analyzed  data being output to easy to see panel  meters which are located directly next  to the press. During the change over to  another piece of glassware the operator  will monitor this critical subset of  parameters at the press for adjustment  of the process. Once the operators are satisfied with the quality of the  glassware being made they can better monitor the production from the local control room and select more detailed displays of  the press activity (Figure 3) by way of selectable front panel screens. 

Figure 3