Automation of transfer in IBC

The client wanted to automate the process in 4 transfer stations, with polyol and isocyanate fluids. All intermediate bulk containers (IBC) were placed in a warehouse for production. The customer’s wish was to dispose of the need to monitor the level and manually transfer fluids from other prepared IBCs. The task was to automatically transfer the fluid to a new IBC with a hose connected and an open stopcock when the level fell below 5% (inclusive).

Customer profile

Grammer CZ is a manufacturer of front and rear console armrests for passenger cars, passenger train seats and other plastic parts. They assemble seats for truck and off-road vehicles, including foaming.

Execution

HW modification was prepared by the customer. Our employees installed the pump, including all sensors for monitoring liquids in front of the pump, levels in the IBC and rebuilt the valves. They replaced the manual tilt handle with pneumatic pistons for IBC tilt.

Complications
Strips were installed on the IBC to monitor the levels. However, two of them were not reliable and were replaced by ultrasonic sensors. The system has been reliable in the long-term with the replacement.

Control module
The Siemens ET 200 module was added to the existing PLC, through which it is used to control the entire process.
In cooperation with the customer’s electrical engineer, the cabling for the new HW was subsequently connected and all elements were tested one by one. The newly installed technology was gradually put into automatic operation.

Result

In total, 4 transfer stations were successfully put into operation within 2 projects.