Our customer has a large log saw with a log feed motor and requires to optimize efficiency of the cutting operation.
The log feed motor speed is controlled by the 4-20 mA output scaled from the saw blade motor current. As the saw motor load increases above 90% load, the log feed motor slows. If the load increases above 120%, the feed motor stops. If the load increases to 150%, the saw motor stops.
Our customer operates an automatic cut-to-length guillotine. A Texmate 320 Series programmable meter controller has been installed and programmed to measure length from an encoder input. Setpoint 1 is programmed to operate at the required cut-off length. A clutch and a clamp operate to stop the metal feed motor.
The Texmate 320 Series bargraph controller samples at 50 times/second for this application. The press operates at 60 strokes/minute. The load cell output is rapidly changing up and down during each stroke of the press. The operator requires the display to be held at peak value for as long as practical.
O2 is an important parameter to measure and control in kilns and furnaces. The diagram below shows the Tiger 320 Series DI-50 controller connected to a Zirconia O2 sensor with a built-in thermocouple.
The controller calculates the O2 level from the temperature and mV level of the sensor. The result is then displayed on the controller.
Wet and dry bulb humidity measurement, using two temperature sensor probes, is perhaps the most reliable method of accurately calculating humidity for low temperature applications in industry today. Both sensors are mounted close together, with one designated the dry bulb sensor and the other the wet bulb sensor. The wet bulb is kept wet using a moistened cotton wick.
The wet bulb is cooled relative to the dry bulb by heat loss due to moisture evaporation from the wet bulb wick. The rate of evaporation is dependent on the ambient temperature and humidity.
Frostmate is an integrated frost risk management system that reduces the risk of frost damage to an orchardist's crop. A sophisticated control and monitoring system constantly monitors the orchard environment combining both temperature and humidity to deliver a reliable prediction of frost conditions. When frost damage is imminent, the Frostmate automatically initiates the timely delivery of water spray to the area at risk, raising the humidity level. Water delivery is maintained in a continuous cycle to the affected zones until the frost conditions have abated, ensuring better crop protection and conserving resources such as water and power.
Our customer has a feed roller system. They require to monitor and maintain a constant pressure between the two ends of the bottom roller to maintain a straight feed.
The bearings at each end of the bottom roller are mounted on a separate load cell. The output from each load cell is connected directly into a Tiger 320 Series controller.
Our customer manufactures machines for loading produce into bags at preset weights. A conveyor carries the produce to the bag. The conveyor speed controller slows the conveyor when the bag nears the required weight. The bag is hung from a load cell which feeds the weight to the Tiger 320 meter controller. When the bag is near the required weight, a setpoint in the meter slows the conveyor. When the bag reaches the required weight, the meter automatically compensates for produce inertia and determines when to stop the conveyor and close the conveyor feed gate. The display flashes between "BAGFUL" and "WEIGHT".
The operator unclamps the bag, and the meter counts and totalizes the bag number from the bag clamp microswitch pulse. The operator fits a new bag and the clamp closes after a 1 second delay to stabalize the load cell.
Our customer requires varying amounts of primary and secondary chemicals to be mixed by ratio. To improve mixing, accuracy and save time, the ratio calculation is automatically performed by a macro.
A container is placed on a weighing platform and the platform is tared to 0. The primary product is poured into the container. The operator enters the required mix ratio and presses the start button.
Our customer operates a gas dispenser that fills gas cylinders of unknown volume and calculates the cost in dollars.
The meter automates the control process through a macro. In the diagram below, both valves 1 and 2 are CLOSED at the beginning of the process (the default position). When the hose connects to the gas cylinder, the safety switch triggers the macro. Valve 1 OPENS, pressurizing the small reference cylinder of known capacity, and the meter stores the pressure data measured from the pressure transducer.
Our customer has a tank supported on a load cell and requires to dispense measured amounts of product from the tank.
Texmate installed a Tiger 320 Series DI-50E meter calibrated to indicate the product weight in the appropriate engineering units. The meter is installed with two remote push-button switches configured as TARE and TARE CLEAR. All non-application codes are blanked out. Relay 1 is connected to the tank outlet valve. The amount of product required is programmed into the meter at setpoint 1. Setpoint 1 is programmed with initial startup inhibit and relay latch OFF. _(See Setpoints & Relays Supplement (NZ201) for full details.)_
**Avoid costly motor and speed controllers for filling applications by using precise digital setpoint tracking.**
The combination of a DI-60A programmable meter controller fitted with a smart load cell input module does just this, delivering accurate and reliable digital process control.
The container is placed under the tank outlet. The start button is pressed, the display is reset to zero (Tared), the valve opens and the motor starts running until setpoint 1 is reached. The motor switches off and before the motor and pump stop completely (due to the motor inertia), the fill weight is reached and setpoint 2 is then deactivated at the fill weight and the valve closes.
Our customer has a semi-automated mixing tank and uses a level sensor to detect the tank level. The tank is filled with a primary solution to a reconfigurable percentage of the full tank, controlled by a setpoint. A secondary solution is then added by hand.
Texmate installed a Tiger 320 Series DI-60AT programmable meter controller (PMC). The controller is calibrated to display the percentage in hundredths of a percent (000.00%). When the pump fills the primary solution to the selected percentage, the setpoint relay stops the pump and the controller scrolls the
A bakery customer has two tanks containing a release agent that is sprayed into the baking trays. If the release agent runs out, the bread sticks to the trays. Two release agent drums, TANK 1 and TANK 2 are placed onto two independent load-cell platforms and both load cell outputs are connected to a dual load-cell input module installed in a DI-60AT controller.
1. On start up, TANK 1 valve is open.
2. When TANK 1 low level (set-point 1) operates, TANK 1 valve closes and TANK 2 valve opens.
3. The system is now operating from TANK 2.
4. TANK 1 is replaced, TANK 1 low level alarm is now OFF.
5. When TANK 2 low level alarm operates, TANK 2 valve is closed and TANK 1 valve is opened.
6. The sequence is repeated.
Bubbler systems are ideal for level measurement of open channel run off systems or duct and tank situations where debris, foam, steam, or surface turbulance makes standard methods of level measurement impractical.
Outdoor growers in intermittent or low rainfall areas require irrigation controllers. The controller input is usually from a tipping bucket rain gauge or a flow sensor.
Control requirements: If more than X amount of rain falls within a programmed time, the irrigation cycle is interrupted. If Y amount more rain falls within the programmed Off-time, the irrigation cycle is interrupted for a longer time.
Our customer manufactures machines for applying labels to cans. They require a controller to control the temperature of the glue and glue roller. The controller also needs to control the length of time the feed mechanism operates to feed the label over the glue roller and spin the can to apply the label.
Texmate installed a Tiger 320 Series DI-503 3-display programmable meter controller (PMC). Two thermocouple inputs control the temperature of the glue and the glue roller and inhibit the machine so that it will not operate unless the glue temperature is within set limits.
A timer controls the clutch, which controls the label feed and can spin time. The timer is configured for 0.001 seconds resolution and is easily adjustable by the operator.
The melt pressure of a plastic extruding or moulding process is an important parameter to measure and control. However, to obtain a reliable reading of the melt pressure requires the pressure transducer to be calibrated at the melt temperature of the plastic. For moulding machines that are used with more than one type of plastic, calibration must be performed for each type.
Our customer requires the amount of resin and roving used during their manufacturing operation to be calculated, monitored, and recorded on a job-by-job basis, providing them with accurate costing and stock information.
Texmate installed a Tiger 320 Series controller and connected it to the resin feedline flow transducer and the roving weighing platform pressure transducer.
The Tiger 320 Series controller using a pH sensor input module operates directly with standard pH sensor outputs.
For quick and easy sensor calibration, the Tiger 320 Series controller has On-demand single and two-point calibration functions from the front panel program button.
The customer has an application that requires to:
1. Display Amps from a DC shunt.
2. Display and control from dual totalized amp/hrs.
The amp/hrs from totalizer 1 operate Setpoint 1.
At programmed amp/hr intervals, a pump starts for a programmed On-time to pump replenishment chemicals to the plating tank.
When Setpoint 1 energizes, totalizer 1 resets to 0, the pump cycle starts, and the amp/hrs totalizer 1 restarts.
Our client has multiple customers on a DC power supply system and needs to know the watt hours (W.hr) or kilowatt hours (kW.hr) used by each customer. Texmate installed a Tiger 320 Series DI-50E meter to measure the DC volts from the power supply on Channel 1 and the DC amps from a DC shunt on Channel 2. The meter records the result of Channel 1 x Channel 2 as W.hr or kW.hr and continually displays this on the operational display.
It is no longer necessary to use combinations of transducers to achieve a power measurement and control system.
A Texmate Tiger 320 Series DI-503 meter, installed with a single-phase power input module, calculates and displays volts, amps, Hz, watts, watt hours, and power factor from a single-phase 2 or 3-wire voltage and current input.
Demand and peak demand are important measurements for large consumers of electricity. This is because the price utilities charge for electricity is related to the peak usage of the consumer over the billing period.
The **Electronic Demand Meter** from Texmate is ideal as a submetering system that can measure and track demand and peak demand in different parts of the factory. This information can then be used to manage the overall peak demand strategy of the factory.
If the real-time clock option is installed in the **electronic demand meter**, the meter can log or print the time the peak demand occured.
The 6 setpoints can be used for load switching or alarms.
If an IWO2 watt input module is installed, the amps, volts, frequency kW, and kWh power factor readings can be viewed by using the UP and DOWN buttons.
In many industrial applications it is necessary to be able to control a device manually. Often a potentiometer or rotary switch is used, but this method can be too coarse and not easily repeatable. Texmate have developed a versatile and easy-to-use selection of manual stations, using their Tiger 320 Series controller, that produce an accurate, digitally controlled and scaled 4 to 20 mA or 0 to 10 V output.
Our customer requires a quality control test for watt/hour rating of electrical appliances. The test is carried out over 5 minutes. A Texmate DI-50E meter with a watt input module is installed. The meter is programmed to totalize the watt/hours when the start button is pressed. The meter totalizes the watts for 5 minutes and the watt/hour rating is held on the display.
For quality control, our customer requires to measure the resistance of hot copper coil windings. Texmate installed a Tiger 320 Series DI-50E meter. A constant current is passed through the coil and the resistance calculated. To compensate for temperature variation the infrared sensor monitors the coil temperature.
As a programmable meter controller (PMC), the Tiger 320 Series is adaptable to one-off final assembly and quality control test jigs. The modular design of the PMC and the vast choice of input signal conditioning modules, allows production engineers to overcome many quality control challenges.
Our customer has a motor generator in a large room. The room temperature is controlled by opening and closing ventilation louvers using a forward and reverse motor. When the temperature rises above the setpoint, the louver actuator motor operates for a programmed ON-time opening the louvers 10 degrees. After a programmed OFF-time, if the temperature is still above the high setpoint, the louvers open in 10 degree degree increments until the temperature falls below the high setpoint.
Our customer has a greenhouse. The greenhouse temperature is controlled by opening and closing the roof vents using a forward and reverse motor. When the temperature rises above the setpoint, the vent actuator motor operates for a programmed ON-time opening the vents 10 degrees.
After a programmed OFF-time, if the temperature is above the high / high setpoint, the vents open in 20 degree increments until the temperature falls below the high setpoint.
Our customer has greenhouses. The greenhouse temperatures are controlled by opening and closing the roof vents using a forward and reverse motor. When the temperature rises above the setpoint, the vent actuator motor operates for a programmed ON-time opening the vents 10 degrees.
After a programmed OFF-time, if the temperature is above the high setpoint, the vents open in 20 degree increments until the temperature falls below the high setpoint.
Our customer operates a fruit packhouse. His customers deliver their fruit in large bins for grading, packing and distribution.
The full bins are loaded onto a conveyer and then transferred to a load cell weighing platform.
The bin raises to a weigh position and then stops. After a 1 second delay (load cell to stabilize) the full bin is weighed. The bin then raises and tips the produce onto a second grading conveyer. The bin then returns to the load cell weigh position and stops. After a 1 second delay the empty bin is weighed.