Control & monitoring.

CIM software for plastics processors continues to become more modular and more open, giving users the power to create systems that fit their monitoring needs and network requirements. At NPE, CIM systems once built around proprietary architectures appeared in newer client-server versions. And the more "modular" approach to CIM - where the users buy only the software pieces they need - has given rise to lower-cost entry-level systems. This push toward more modular systems has also resulted in new production-control products, such as drag-and-drop schedulers, from companies that once specialized in process monitoring.

CIM FOR DIFFERENT BUDGETS

As a successor to its Focus 2000 process and production monitoring system, Syscon-PlantStar of South Bend, Ind., launched three new CIM systems targeted to different user needs and price levels. All are PC-based client-server systems with Windows user interfaces. Entry-level versions can be upgraded to higher levels.

* SnapShot, the Windows 95 or 3.11 entry-level system, now uses a single data-collection box to monitor production information from up to 32 machines. Data can be viewed on up to three PC terminals. All-inclusive price is under $10,000 for 16 machines, under $13,500 for 32 machines.

* Portrait, the mid-level CIM system with an SCO-Unix operating system, can monitor up to 70 machines and offers more sophisticated scheduling, reject-tracking, and process-analysis tools. Up to 12 PC terminals can be networked. Price starts at $25,000.

* Panorama, the expanded system, fits most closely the niche of the former Focus 2000 system, and it has no practical limits on the number of machines or PCs it can handle. It includes a new custom report writer and the ability to track different parts made in family molds. Unlike Focus 2000, its host software runs on a PC/UNIX platform that costs less than the previous IBM RS6000 computer. System cost is now 10-15% lower - starting at around $32,000.

TRACKING PRODUCTION

Well known for its process-monitoring systems, RJG Technologies of Traverse City, Mich., has crossed over into production monitoring with its new PartNet system. Running on Windows NT or 95, PartNet handles up to 500 machines, providing real-time production reporting, scheduling, quoting, and accounting. The rule-based scheduler allows users to constrain their schedules based on real-world factors such as tonnage requirements, operator availability, or auxiliary-equipment needs.

While PartNet will be marketed as a stand-alone package, users of RJG's process-monitoring system will be able to use the same data for both production and process monitoring. This client-server system will cost roughly $15,000 for the host software and up to four simultaneous PC users.

RJG also showed the new Windows version of its process-monitoring system, called DartVision

'WINDOWS' ON YOUR PROCESS

Other firms introduced new Windows-based process and production monitoring products at the show:

* Branden Technologies of Wilsonville, Ore., released Version 1.5 of its Windows NT-based Shotscope system. Among the new features is a document viewing package that lets users embed text, tables, pictures, drawings, video, and audio in shop-floor screens. The goal is "to eliminate paperwork on the shop floor," says a company official. Other enhancements include a new color touchscreen user interface, and new alarm capabilities such as an "early warning" about process variations.

* Hunkar Laboratories, Cincinnati, brought out several new Windows-based open-architecture CIM products, including the Win-PPM network server. It's a Windows 95 or NT version of the low-cost process-monitoring system introduced last year. A 10-machine system costs around $19,500.

* Hunkar's new Class-Meter IV process monitor and control terminal is preprogrammed for a specific process (injection molding, extrusion blow molding, injection-blow, or stretch-blow). For users who want more flexibility, Hunkar's new open-architecture Matrix universal process monitor and controller is completely user-configurable for any kind of process.

* Barber-Colman Co.'s Industrial Instruments Div., Loves Park, Ill., unveiled Foxtracker PC-based supervisory systems for networks of machine controllers from Barber-Colman or other vendors. Foxtracker systems are preconfigured for injection or blow molding or extrusion. Part of the new I/A Series of Windows NT systems, these are turnkey packages of hardware and software for process and production monitoring, as well as scheduling. Complete installed price starts at $25,000 for a four-machine system.

STAND-ALONE SPC MONITOR

Among several new CIM products brought out by Mattec Corp., Loveland, Ohio, is a stand-alone SPC and process analyzer that provides all the information needed for machine capability studies or individual machine process documentation for ISO/QS 9000. (For other new Mattec offerings see New Products.)

The SPC analyzer is a low-cost solution for plants that need to monitor only one or a few machines, and it can later be incorporated into a full-fledged CIM network. Different versions are available at prices from $3900 to $8000, depending on type of display. The standard system can monitor 20 variables (up to 96 are possible) and display SPC charts right at the machine. It can interface with digital calipers or weigh scales to correlate process data and part attributes. Users can also log scrap and downtime codes.

DROP SCHEDULES INTO PLACE

"Drag-and-drop" is the latest fashion in scheduling software, judging from its frequent appearance at NPE. One of the new examples of this feature comes from Mascon of Schaumburg, Ill. The company's new scheduler for its AIMS manufacturing management software lets users set up and reconfigure schedules by using a mouse to move jobs around on a Gantt chart. The new scheduler also has enhanced recognition of capacity constraints such as machine size, color-change considerations, labor availability, auxiliary-equipment needs, and set-up complexity.

Another handy feature is the "time fence," which sets aside blocks of time that are not subject to rescheduling. A similar feature called "Job Anchor" does the same thing for individual jobs. Also, a new automatic optimization tool moves production forward to fill unused blocks of time.

A drag-and-drop scheduler is part of the new R3 production-management software from Nicollet Process Engineering, Minneapolis, that runs in conjunction with company's Windows NT process-monitoring system.

Nicollet also introduced an entry-level production-management system, called PMRS, which captures production and productivity data. Because it is built on the same modular Windows NT architecture as the company's other systems, users can easily add full process monitoring later.

RELATED ARTICLE: New Controls & Sensors Debut at NPE

In addition to monitoring systems, NPE saw several previously unreported introductions of process controls and sensors.

* PLC process controls: Rockwell Automation/Allen-Bradley, Mayfield Heights, Ohio, will release new pre-programmed process-control modules for its low-cost SLC Series of small logic controllers. The first of these modules will be available in early 1998 for blow molding machine control and parison programming. A similar product for injection machine control, the ProSet 200 for the SLC 5/04 platform, will soon be available as well.

* Barrel-temperature control: Rockwell Automation came out with two new barrel-temperature controls for injection and extrusion. The 1746 BTM is a new module for improved multi-loop control. Rockwell also extended the barrel-temperature control capabilities of its PLC-5 controller to accommodate RTD inputs.

* Customize control displays: Rockwell Software of Milwaukee released a new version of RSView32 man-machine interface software for Windows 95 and NT.

Graphical control screens can be easily customized. The system replaces proprietary scripting languages with the Visual Basic for Applications language used by Microsoft word-processing, spreadsheet, and database programs. In a demonstration of the new software's real-time internet communications capabilities, Rockwell monitored 13 molding machines in Milwaukee from an RSView32 work station at NPE.

* Supervisory temperature monitoring: Syscon-RKC, South Bend, Ind., rolled out the ViewNet T100 touchscreen operator interface, which can communicate with up to 300 RKC temperature controllers. New Panel Designer PC software allows for custom screen design.

* Cavity-pressure sensors: Kistler Instruments of Amherst, N.Y., came out with a low-cost, piezoelectric, behind-the-pin pressure transducer for applications not needing direct sensing. Price is $545.

RJG Technologies has a new T-6157 flush-mount, strain-gauge cavity-pressure transducer.