fill level Archives - AUTOMATION INSIGHTS

In a previous post, 3 Smart Applications for Process Visualization, we discussed how the term “process visualization” has evolved since the introduction of the SmartLight. While it can definitely be used as a stack light, its additional modes can be applied for all sorts of different operation/ process visualization tasks. Below are a few more examples we’ve come across.

Use Case #4: Fill Level Status:

From micro-breweries to steel-mills and oil refineries, all have state-of-the art tack fill level detection systems measuring fill levels to the last millimeter or in some cases cubic inches. But when you want to take peek at the how much the reservoir is full at any given time- you have to go to the HMI in some corner to see that value. Nine times out of ten this fill indication provides you only with numerical value. What if SmartLight shows you the value visually using the level mode of operation? Then the decision to run another batch of bottle filling can be taken without going to that corner and punching some numbers. Additionally, the colors of the segments can be changed to indicate the temperature or pressure inside the tank or just different fill levels so the line supervisors can take decisions promptly on the next action.

Use Case #5: Interactive Operator Status:

Several times plants invest in huge TV monitors to provide a real-time visual feedback to their employees on how their operations are progressing compared to the quota assigned. At one plant, they found no increase in employee productivity with such investment because the TV monitors failed to provide a visual feedback. The television sets indicated 112/300 – which meant nothing to the operators. The SmartLight, however, provided them the feedback using the level mode of operation on how they are performing to the quota. The moment SmartLight turns yellow was an indication to the operator(s) that they are falling behind the level of the lighted LED indicated that they are closing the gap to their daily quota. If the operator notices problems with the batch of components or machine itself they could change the SmartLight to a run light mode with a push of a button indicating trouble in the workcell – the supervisor then can deploy the right maintenance person to the cell. Utilizing the SmartLight light not only provided instantaneous feedback on performance but also added efficiency in handling production issues.

Use Case #6: Improving Hazard Awareness:

In one automotive plant, the maintenance team designed an innovative solution with SmartLights for hazard communication. This plant has several automated guided vehicles (AGVs). The light indicators on these AGVs are the same type that was on the mast of most of the workcells in the plant. It was hard to notice when the AGVs were pulling out of and entering their parking stand. Maintenance engineers installed SmartLights on the mast of the AGV parking stand and with different color scheme and level mode indicated if the AGV is coming to stop or just starting the motion. This simple idea avoided daily occurrences of mishaps for the forklift drivers and operators.

Use Case #7: Identify Bottlenecks:

With linear assembly process it can be difficult to detect bottlenecks in the production process. With increase complexity of today’s production flows the bottlenecks dynamically change under various conditions. Installing SmartLights programmed to change their mode of operation depending on certain conditions (on-demand change of mode) could help point out bottlenecks in the current environment. For example, these days the automation controllers are equipped to calculate its overall equipment effectiveness (OEE). That information can be directed to the SmartLight. A specified segment may turn green when OEE >80%, turns yellow when 60% < OEE < 80% and red if the OEE falls below 60%. Now, the plant supervisors can see the overall picture of the entire floor to make informed and timely decisions.

Use Case #8: Time Lapse Counter:

Wouldn’t it be nice to know how long it takes to replenish the stack of pallets in the robotic palletizing cell? Or how often the operator has to go into the cell (causing stop operations) for mis-fired sensor or dropped package? How about break-times for the operators? Well SmartLights can be used for all these types of operations. This can be done by changing the blinking frequency of the SmartLight segment, and changing the colors or modes of operations, a multitude of information can be displayed for various purposes.

We want to hear from you! Do you have a unique application for the SmartLight? Share your story with us here.

You can also learn more by visiting our website at www.balluff.us.

In a previous entry here on the SensorTech blog, we discussed the concept of liquid level sensing, and the difference between discrete liquid level detection and continuous liquid level monitoring. In this entry, we are going to talk about the requirements for liquid level sensors that are used to measure or monitor liquid products that will ultimately be consumed by humans.

In these applications, it is necessary and critical that sanitary standards be met and maintained. Sensor designed for sanitary applications are usually designed from the ground up to meet these requirements.

Basically, there are two key criteria that come into play when considering the suitability of a sensor to be used in a sanitary environment:

Cleanability – Sanitary filling systems typically need to be regularly cleaned and/or sterilized to prevent the growth of potentially harmful bacteria. It is desirable in most cases that the cleaning/sterilization process be done as quickly and as easily as possible, without having to remove components (including sensors) from the system. For this reason, many sanitary fill sensors are designed to withstand “cleaning-in-place” (CIP). Factors such as water-tightness, and ability to withstand elevated cleaning solution temperatures come into play for CIP suitability.

Mechanical Sensor Design – Sensors for sanitary fill applications are usually designed such that there are no mechanical features that would allow liquid or debris to collect. Crevices, grooves, seams, etc. can all act as collection points for liquid, and can ultimately lead to contamination. For this reason, sanitary sensors are designed without such features. The physical make-up of the sensor surface is also important. Exterior surfaces need to be very smooth and non-reactive (e.g. high-grade stainless steel). Such materials also contribute to cleanability.

Consistent standards for sanitary equipment, products, and processes are defined and maintained by 3-A SSI, a not-for-profit entity that provides consistent, controlled, and documented standards and certifications for manufacturers and users of sanitary equipment, particularly in the food, beverage, and pharmaceutical industries. Equipment that meets these sanitary standards will usually display the 3-A symbol. For more information on this solution visit the Balluff website.