SCADA Online Product Quality Control

Abstract

Controlling the quality of the product during the manufacturing phase is the process of analysis, control, management of factors and variables that affect the quality of the final product. Integrating the computer in the industrial manufacturing control will ensure the quality of the product, as well as to provide the necessary data for the production process progress, the ingredients ratio used in each production batch and statistical data of the changes that may occur in the composition of the product. Traditional methods to control the quality of the product are inadequate and inappropriate; they need to be changed to keep pace with the huge development in the field of industrial automation, control systems, industrial quality and computer technology used in various industries as well as clear development in the field of industrial sensors. This study falls into three-research area: integration of SPC and EPC, SCADA batch processes monitoring and control, and concrete batching plant. The objectives of this study are (a) To design a SCADA system for batch process monitoring and quality management, (b) To establish an integrated SPC/EPC methodology for a batch process, and (c) to illustrate the proposed approach with an application of the analysis and monitoring of an industrial concrete batching plant. The concrete batching plant has different batch processing subsystems, but the aggregate batching process has the greatest impact on product quality, unfortunately, this industrial process is poorly automated, in most plants in Gaza strip. The traditional control or even the manual control is still common which leads to uneven mixtures and inconsistent product quality subject to several disturbances. A complete PLC system is designed for full-automated concrete plant, with new aggregate weighing and batching algorithm implemented for adaptive flow rate and feeding speed control. Through this study ,the implemented algorithm and SCADA system , process engineers at the industrial plants are now able to use a valuable decision making tool when the production process is affected by certain disruptions, with obvious consequences on product quality, productivity and competitiveness.