SmartConnex Feeder Controls
SmartConnex Control Environment for Feeders
Coperion K-Tron's machine controllers and operator interfaces deliver full functional flexibility and the connectivity you need. Coperion K-Tron’s SmartConnex control environment provides comprehensive control capability with maximum flexibility and connectivity for systems up to 24 weigh belt feeders, loss-in-weight feeders, volumetric feeders, batchers, flow meters, Bulk Solids Pump (BSP) feeders or PID controlled devices as well as pneumatic refill systems.
Simple Control Architecture
Each SmartConnex control system comprises a combination of the following control components: a Control Board & Motor Drive Module (KCM) for each feeder and an optional Operator Interface.
SmartConnex offers a choice of two operator interfaces: KSU-II Single Unit Interface or K-Vision Line Controller for multiple line control. These display and data entry units can be employed individually or in combination as required by the application.
KCM Control Module
The Coperion K-Tron Control Module (KCM) combines feeder control and motor drive modules into a compact housing, offering more flexibility and excellent performance. Each feeder has its own KCM, generally mounted directly on the feeder, which is available in various configurations depending on the application.
KSU-II Single Unit User Interface
The KSU-II is an economical user interface for single feeders with KCM. It can also be used as a portable display for maintenance or configuration in larger systems where the feeder‘s primary display point is a higher level unit. The KSU-II can be dedicated to a single feeder or it can network to multiple KCMs. The KSU-II will only view one feeder at a time, but the user can switch between feeders.
K-Vision Line Controller
The K-Vision™ controller simultaneously controls max. 24 devices in up to two lines. Operator interface is via 12.1 inch color LCD with a touchscreen. K-Vision provides recipe entry and a detailed overview of the process line with extensive real-time monitoring of feeder status and performance. This user friendly HMI offers a wide range of easily configured charting and trending capabilities.
The Screw Speed Modulation algorithm adapts the drive command to minimize massflow pulsation
Single screw loss-in-weight feeders operating at low rates often produce an unsteady discharge within one revolution of the screw, resulting in mass flow pulsation. Coperion K-Tron’s exclusive Screw Speed Modulation algorithm records the pulsation and adjusts screw speed to compensate for the effect, minimizing mass flow variability and ensuring smoother discharge.
• Short-term accuracy improved by a factor of 2
• 2-Sigma accuracy at a 10 second sampling time improved tremendously
• Ideal for low feed rates (speed < 1 screw rotation per second)
Smart Refill Technology improves accuracy during feeder refill
During loss-in-weight hopper refill, sensed weight is not useful to control feed rate. While others simply freeze screw speed until refill is complete, Coperion K-Tron’s exclusive Smart Refill Technology memorizes recent gravimetric performance at various hopper weights and varies screw speed to compensate for changes in material density during refill. This maintains accurate performance and enables a smoother transition to full gravimetric control.
Dynamic digital filtering minimizes weigh errors due to environmental influences
Achieving high gravimetric feeding performance on the process line requires discriminating between weight data and the contaminating effects of inertial forces induced from ambient vibration and shock. Coperion K-Tron’s exclusive dynamic digital filtering algorithm continuously identifies and extracts spurious inertial components from the weight measurement, even in severe process environments.
Continuous Gravimetric Extrusion Control
Coperion K-Tron’s Continuous Gravimetric Extrusion Control package offers the ability to control extruder speed so that its output has a predictable and repeatable mass flow. By accurately measuring material throughput, gravimetric extrusion control can compensate for material and process variations and provide more consistent end product quality. This technology is most often used in conjunction with single screw, flood-fed extruders. The most common applications are: profile extrusion, cast sheet, blown film, cable coating, laminating, precision tubing, and pipe extrusion. Gravimetric extrusion control is virtually a necessity for multi-layer coextrusion systems. The Coperion K-Tron package offers a fully integrated feeder and control solution with mass flow or weight per length control, allowing the processor to set the extruder speed from the Coperion K-Tron interface.