| LineMaster™ Extrusion Control |
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| Increased
Productivity, Yield and Uniformity for All Continuous Extrusion Processes
You Can Avoid Yield and Productivity
Losses…
by Installing LineMaster on Your Existing Extrusion Lines
The Maguire LineMaster system is simple to operate
and cost effective. It works perfectly with all types of extrusion
processes to ensure a uniform, quality product. From mono-layer, single
extruder lines to multi layer co-extrusion lines LineMaster provides a
solution that is both simple and cost effective. |
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Benefits of LineMaster™
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Improved product quality through permanent
and consistent
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Reduced material costs through improved yield. |
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Automatic regulation of extruder output. |
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Increased line productivity with fast start-up
and reduce scrap. |
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Quick product changeover. |
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Alarms and user security. |
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Control Options
Production is effectively controlled by any 1
of 3 methods:
Method 1 -
Throughput (lb/hr or Kg/h) – XC-1
Method 2 - Weight per Length (lb/ft, g/ft, g/m, kg/m) – XC-2
Method 3 - Weight per Length, Dual Control (lb/ft, g/ft, g/m, kg/m) –
XC-3
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Throughput (lb/hr or Kg/h) – MODEL XC-1
XC-1 is ideal for simply controlling the throughput of an Extruder
or Starve Feeder. Applications include simple lb/h or kg/h extruder
control where other downstream equipment is already automating the
Take-Off control, for example online gauging or IBC (Internal Bubble
Cooling) control.
Weight per Length (lb/ft, g/ft, g/m, kg/m) –
MODEL XC-2X, XC-2T
XC-2X Weight per Length control via
extruder drive
XC-2X is ideal to control the output of an Extruder or
Starve Feeder. Typical application is to control Weight per Length
(lb/ft, g/ft, g/m, kg/m) where other downstream equipment may already be
automating the Take-Off control, for example, online gauging or IBC
(Internal Bubble Cooling) control.
XC-2T Weight per Length Control via
Take-Off drive
XC-2T is most commonly selected for mono layer lines. The
line speed is determined by the digital encoder mounted on any rotating
shaft or roll of the Take-Off. Using the throughput information (lb/h or
kg/h) from the extruder, the actual weight per length of the film
product is calculated in grams/m. The control of the Take-Off drive,
which often has a much finer resolution than that of an extrusion drive,
is then maintained automatically, adjusting the speed of the line up or
down in relation to extrusion output.
Dual Control (lb/ft, g/ft, g/m, kg/m) – MODEL
XC-3
XC-3 Weight per Length Control (lb/ft, g/ft, g/m,
Kg/m), or Calculated Gauge Control (mil., micron) of both Extruder and
Take-Off Drives XC-3 can be used on mono layer lines where a user wishes
to automatically control both the extruder output and the Take-Off line
speed. XC-3 is ideal for use on multi layer, co-extrusion lines. XC-3
operates on the Main layer – the Master layer of the co-extrusion line,
and controls both the speed of the extruder drive and speed of the
Take-Off. The Side layers, or Slave layers, are controlled by an XC-1
Throughput
Control on each layer. To co-ordinate the layers and total line output a
Touch Screen Panel PC is used with the XC software to accurately
coordinate the throughputs to each layer accurately and maintain correct
line speed. Control can be managed by either Weight per Length (lb/ft,
g/ft, g/m, kg/m) or Calculated Gauge Control (Micron or Mil.).
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LineMaster™ Hardware
The design of LineMaster is modular to allow
easy selection of the components required for either a mono or
co-extrusion film line.
Core Components LineMaster is comprised of
two key components:
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LIW Loss-in-Weight Hopper |
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The LIW Loss in
Weight hopper is sized to suit the maximum possible output of a mono
or coextruder layer of a line. The range of LineMaster Loss in
Weight hoppers cater to every application of free flowing material,
pellets, granules or powder, and incorporates a controller for the
LineMaster. Key information is summarized on the display.
Each LineMaster hopper monitors the loss in
weight of material as it flows into the extrusion line. The hopper
is suspended on a pair of highly accurate load cells, which are
sized according to throughput. The control on the LineMaster hopper
monitors weight, reading and updating the throughput calculation
every second in lb/h or kg/h. This basic information is provided to
the system so actual product throughput or weight per length can be
calculated and controlled.
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XC Drive Control Package |
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The XC Drive
Control Package provides the interface between the LineMaster
Controller and either Extruder Drive, Take-Off Drive, or both. There
are 4 different ways the LineMaster can automate the control of a
line, and these choices are fully defined in Control Selection.
Every XC Drive Control Package includes an XCD-X
(X= Extruder) or an XCD-T (T= Take Off) Interface Box. The packages
also include interfacing cables and encoder where relevant.
The XCD Interface can be mounted inside the
control cabinet or externally on the control cabinet, depending on
how the existing controls are mounted on an individual film line.
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Digital Encoder |
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A Digital Encoder
with a 12” / 300mm Wheel is also supplied with XC-2X, XC-2T and XC-3
Drive Control Packages where Line Speed needs to be determined.
The encoder is mounted either direct to a
drive shaft on the nip roller or mounted with the wheel on a roller.
This accurately monitors the Line Speed to calculate then the weight
per length and or gauge of films being produced. The encoder is
supplied with a pre-prepared 100ft / 30.4m cable to connect the
encoder to the XCD Interface Card. |
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Four key functions the Interface Box performs.
- Provides the Interface Card that terminates all
wiring from the drive, the encoder and the LineMaster controller.
- Communicates and displays the voltage from the
LineMaster Controller to the drive being controlled.
- Includes a toggle switch to change from
‘Manual’ control of the line to ‘Lock’ (Automatic) control by the
LineMaster controller.
- Incorporates a digital potentiometer which
replaces the existing rotary drive speed control on the extruder drive
panel and communicates with the XCD Drive Speed Control to control the
line. For lines with PLC Controls there is a Follow or Trim mode in
the LIW Controller that allows the existing controls to be utilized as
before.
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LineMaster™ Control
Selection
LineMaster offers three basic control packages
for mono or co-extrusion lines. Each one is simple to operate and
designed for easy installation.
Throughput Control of Extruder
or Starve Feeder (lb/h or kg/h) MODEL XC-1
- The LIW mounted on the throat of the extruder
monitors the actual throughput (lb/h or kg/h) of the line.
- Target throughput is set on the LIW Controller
and the operator then switches to ‘Automatic’ mode.
- LineMaster varies speed of the extruder or
starve feeder to maintain the target throughput per hour when in
‘Automatic’ mode.
- The system maintains constant output of an
extruder or starve feeder.
- The LIW controller communicates with the XCD-X
Extruder Drive Speed Control, which adjusts the voltage or reference
signal to the extruder drive. This controls the speed of the extruder
drive and adjusts automatically to maintain desired throughput.
Where to use XC-1 Throughput
Control:
XC-1 is ideal for simply controlling the
throughput of an Extruder or Starve Feeder. Applications include simple
lb/h or kg/h extruder control, where other downstream equipment is
already automating the Take-Off control, for example online gauging or
IBC (Internal Bubble Cooling) control.
XC-2T Weight per Length Control Via Take-Off
Drive (lb/ft, g/ft, g/m, Kg/m)
- The XC-2T and XC-2X Extrusion Yield Control
Package have similar features.
- Primary difference is that the XC-2T controls
the speed of the Take-Off Drive.
- Throughput of the LIW on the throat of the
extruder is monitored in lb/h or Kg/h.
- Line speed is monitored in meters/minute via
the digital encoder mounted on the nip rollers of the Take-Off.
- These two pieces of data are used to
automatically calculate the actual product “yield” in lb/ft, g/ft,
g/m, or Kg/m.
- The Actual yield is compared to the Target set
upon start up of the LIW Control.
- The LIW controller communicates to the XCD-T
Take-Off Drive Speed Control, which adjusts the voltage or reference
signal to the Take-Off Drive
- Product’s weight per length (yield) is
maintained automatically, adjusting the speed of the line up or down
in relation to Take-Off Drive
- The Extrusion Drive is manually controlled when
using the XC-2T
- If the speed of the Extrusion Drive is manually
increased or decreased, the LineMaster control will automatically
adjust the Take-Off speed to maintain constant weight per length.
Weight per Length
Control
Weight per Length Control Via Extruder
Drive (lb/ft, g/ft, g/m, Kg/m)or Weight per Length Control Via Take-Off
Drive (lb/ft, g/ft, g/m, Kg/m)
XC-2X - Weight per Length
Control Via Extruder Drive
- The LIW mounted on the throat of the extruder
provides throughput data in lb/h or Kg/h
- Line speed is monitored in meters/minute via
the digital encoder mounted on the nip rollers of the Take-Off drive.
- These two pieces of data are used to
automatically calculate the actual product “yield” in lb/ft, g/ft,
g/m, or Kg/m.
- The Actual yield is compared to the Target set
upon start up of the LIW Control.
- The LIW controller communicates to the XCD-X
Extruder Drive Speed Control which adjusts the voltage or reference
signal to the extruder drive.
- Product weight per length (yield) is maintained
automatically, adjusting the speed of the line up or down in relation
to Extruder Drive.
- If the speed of the Take-Off Drive is manually
increased or decreased, the LineMaster control will automatically
adjust the extruder speed to maintain constant weight per length.
- The Take-Off Drive is manually controlled when
using the XC-2X
- If the speed of the Take-Off Drive is manually
increased or decreased, the LineMaster control will automatically
adjust the extruder speed to maintain constant weight per length.
XC-2X Where to use?
XC-2X is ideal to control the output of an
Extruder or Starve Feeder. Typical application is to control Weight per
Length (lb/ft, g/ft, g/m, kg/m) where other equipment, downstream, may
already be automating the Take-Off control, for example, online gauging
or IBC (Internal Bubble Cooling) control. Most mono extruders are run
at, or near, maximum output so control of the Take-Off is often
preferable (see XC-2T).
XC-2T Weight per Length Control Via
Take-Off Drive (lb/ft, g/ft, g/m, Kg/m)
- The XC-2T and XC-2X Extrusion Yield Control
Package have similar features.
- Primary difference is that the XC-2T controls
the speed of the Take-Off Drive
- Throughput of the LIW on the throat of the
extruder is monitored in lb/h or Kg/h.
- Line speed is monitored in meters/minute via
the digital encoder mounted on the nip rollers of the Take-Off.
- These two pieces of data are used to
automatically calculate the actual product “yield” in lb/ft, g/ft,
g/m, or Kg/m.
- The Actual yield is compared to the Target set
upon start up of the LIW Control.
- The LIW controller communicates to the XCD-T
Take-Off Drive Speed Control, which adjusts the voltage or reference
signal to the Take-Off Drive.
- Product’s weight per length (yield) is
maintained automatically, adjusting the speed of the line up or down
in relation to Take-Off Drive.
- The Extrusion Drive is manually controlled when
using the XC-2T
- If the speed of the Extrusion Drive is manually
increased or decreased, the LineMaster control will automatically
adjust the Take-Off speed to maintain constant weight per length.
XC-2T Where to use?
XC-2T is most commonly selected for mono film
extrusion lines. The line speed is determined by the digital encoder
mounted on the nip rollers. Using the throughput information (lb/h or
kg/h) from the extruder, the actual weight per length of the product is
determined. For example Kg/h + m/min = g/m. The control of the Take-Off
drive, which often has a much finer resolution than that of an extrusion
drive, is then maintained automatically, adjusting the speed of the line
up or down in relation to extrusion output.
Calculated Gauge Control
XC-3 Weight per Length Dual Control
(lb/ft, g/ft, g/m, Kg/m), or Calculated Gauge Control (mil., micron) of
both Extruder and Take-Off Drives
- The XC-3 Package allows both the extruder and
takeoff drives to be controlled.
- The system includes a LIW Hopper, a controller
with operator interface, extruder drive speed control packages for
each extruder and a Take-Off / Line Speed control package with digital
encoder.
- The LineMaster XC-LMC computer with touch
screen (Maguire Option) is required for simultaneous control of both
extruder drive speed and line speed.
- Two or more Extruder drive controllers
communicate to each other to synchronize the ramp up and down of all
drives as directed by the LineMaster XC-LMC computer.
- The XC-3 is designed to maintain product weight
per length (yield) or Calculated Gauge.
- Material throughput of the LIW hoppers, mounted
on the throat of each extruder, is monitored in Lb/h or Kg/h.
- This data is combined with the line speed,
provided by the encoder mounted on a rotating shaft of the Take-Off.
- Actual product yield or gauge is calculated.
- The actual yield is compared to the desired
target yield of the product entered on the LIW controller.
- The LIW controller communicates to the XCD-X
Extruder Drive and XCD-T Take-off Drive Speed Controllers to adjust
the voltage or reference signal to each extruder drive, controlling
increase or decrease of speed in relation to the line speed to
maintain the desired target yield.
XC-3 Where to use?
XC-3 can be used on mono extrusion lines where a
user wishes to automatically control both the extruder output and the
Take-Off line speed. For multi -layer, co-extrusion lines XC-3 operates
on the Main layer, the Master layer of the co-extrusion line, and
controls both the speed of the extruder drive and speed of the Take-Off.
The Side layers, or Slave layers, are
controlled by an XC-1 on each layer. To
co-ordinate the layers and total line output a Touch Screen Panel PC is
used with the XC software to coordinate the throughputs to each layer
accurately and maintain correct line speed. Control can be managed by
either Weight per Length (lb/ft, g/ft, g/m, kg/m) or Calculated Gauge
Control (Micron or Mil.).
LineMaster™ How it Works
Line Start-up
On a first time start-up of the process, the
control system is placed into ‘Manual’ mode. The operator starts the
line as normal. During this time the LIW Controller learns the rate of
the material flow through the Loss in Weight hopper within 45 seconds.
The line can then be switched to ‘Automatic’ control.
Throughout the whole production process, from
ramping up the film line, reaching target production and then ramp down,
the Loss in Weight hopper is monitoring consumption of material. In
‘Automatic’ mode the system constantly compares Actual versus Target,
and then adjusts the speed of the drive to maintain target set point.
It does this by monitoring throughput into the
extruder every second. The system compares this actual data to target
data. If there is a deviation, the system accumulates a weight error
until it hits a trip point to make an adjustment to the voltage of the
drive under control. The LineMaster system does this continuously,
trimming the drive up or down to stay on target.
Control throughout the refill period is constantly
maintained by intelligent dynamic algorithms in the software of the
LineMaster control, maintaining the control before and after loading, to
ensure line stability and consistency.
The accuracy of LineMaster is extremely consistent
to within +/ 0.5 % of the required target set point.
Line Corrections
During a production run there are many factors
that cause a line to deviate from the Target output required.
All of these make the process less consistent, harder to regulate
automatically and use more energy.
The LineMaster system helps to regulate
fluctuations and stabilize end product to give a more consistent output.
Examples requiring line correction include:
Screen Packing – As contaminates build up
on the screen of the extruder this slows output and increases melt
pressure. Conversely, as screw packs are changed, melt pressure and
output can change again, all of which cause film to vary from the target
weight per length required.
Voltage Fluctuations – Over a given 24-hour
period, power supplies can fluctuate to a plant effecting all drives and
outputs, causing variable outputs on extrusion lines.
Melt Flow Temperature Fluctuations – Heat
and Cooling of screws and barrels can vary significantly due to many
factors, including worn drives, which can cause sheer on materials
leading to variations in output.
Worn Screws and Barrels – Over time, and
depending on materials used and maintenance, screws and barrels can
become worn - leading to variable outputs from an extruder.
Material Mix, Geometry and Density Changes –
Changes in densities or blends of materials impact output
consistency.
XC Drive Control
Packages
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Drive Controlled |
Units of Control |
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Extruder Drive |
Take-Off Drive |
lb/h |
Kg/h |
lb/ft |
g/ft |
Kg/m |
g/m |
Mil. |
Micron |
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Mono Layer Extrusion Lines |
| XC-1 |
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Co-Extrusion Lines |
| Main/Master Layer |
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LineMaster Options
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Model |
Surge
Hoppers |
Stub Tube
Adapters |
Flow
Moderator
Cones |
Drain
Ports |
Controller
Cable Kit |
MXF Starve
Feeders |
XC
Software |
| For All LIW Models |
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LineMaster XC-G2
Networking Software
Optional G2 software offers multiple advantages
for the control and monitoring of extrusion lines.
For XC-1 and XC-2
Maguire G2 software can be connected to LineMaster
to generate reports on material consumption, control performance and
control production lines remotely for XC-1 and XC-2 applications.
- G2 Software is sold as 1 license per each LIW
hopper for Multi Layer Co-Extrusion applications. The program is
typically installed and run from computer, with a touch screen, that
is mounted in or around the central control panel of the extrusion
line. Maguire can supply the touch screen computer or it can be
sourced locally.
- The G2 software can also integrate and control
Maguire WSB Gravimetric Blenders, which are often utilized to dose and
mix blends of materials to Line-Master.
- The software is fully networkable, allowing
access to reports and controls remotely from any other PC on the same
network.
For XC-3
The G2 software program is an integral part of the
XC-3 Extrusion Multi-layer line.
- Control Throughput and Yield
- Monitor and control up to 7 layers; each layer
is graphically depicted (screen shot). All lines visually merge where
the Total Throughput is displayed. Take-off and downstream controls
are displayed at the right showing line speed, weight per length
and/or gauge. A more detailed examination of each blender’s settings
and output can be accessed through the Line Blender Screen by clicking
on the individual extruder.
- The software also allows reporting on average
throughput, total throughput, and the percentage of total uptime of an
individual blender or all blenders on the line. Reports are based on
start/ stop date and time, weight units and percentage of run time.
G2 Software
- G2 Software is sold as 1 license per each LIW
hopper for Multi Layer Co-Extrusion applications. The program is
typically installed and run from touchscreen computer that is mounted
in or near the central control panel of the extrusion line. Maguire
can supply the touch screen computer or it can be sourced locally.
- The G2 software can also integrate and control
Maguire Blenders.
- The software is fully networkable, allowing
remote access to reports and controls from any other PC on the same
network.
3-Layer
Co-extrusion Screen
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7-Layer
Co-extrusion Screen
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Trend Screen
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