Success stories
Steaming system with PLC and synchronized ergonomic positions for a safety footwear manufacturing plant.
Project description
A manufacturer of safety boots needed to optimize a rotary gluing station where operators applied steam to the boots prior to assembly. The manual process generated positioning errors, lack of control over time and pressure, inefficient power consumption and ergonomic problems for the operators.
Original situation:
Challenges posed by the client:
At a new safety boot manufacturing plant, the customer incorporates a rotary gluing station where operators must apply steam to the boots to soften the material just prior to assembly.
Each operator works on 4 boots in parallel, which requires precision, synchronization with the wheel and ergonomics in a highly repetitive operation.
Originally, the steam application process was manual, without synchronization with the rotary station, without control of process parameters and with unergonomic positions for the operator.
This posed the following problem:
- Errors in the placement of the corresponding spoils in each position of the rotating wheel.
- Impossibility to program, adjust and trace process parameters (vaporization times, pressure).
- Inefficient power consumption due to the inability to enable or disable positions individually according to the product to be processed.
- Forced postures and repetitive loads for the operator.
Proposed solution:
Customized steam solution developed by Giconmes.
Proposed solution:
Giconmes developed a fully automated solution consisting of a stand-alone outdoor station with 4 ergonomically distributed steaming positions to facilitate the operator’s work during the assembly process.
Each position was synchronized by means of light signals with the rotary gluing station, indicating at all times the corresponding spoil for each cycle and thus reducing positioning errors in a highly repetitive operation.
The system is controlled by a Siemens Simatic S7-1200 PLC with a 7″ HMI touch screen, from which it is possible to program, monitor and visualize in real time all process parameters, such as vaporization times, pressure or position activation.
The installation incorporates a 15 kW NGV-1700 electric steam generator, made of AISI-304 stainless steel, together with 24V DC solenoid valves, automatic condensate recovery traps and independent activation by position to optimize energy consumption according to the product processed.
In addition, the entire solution was integrated into an industrial aluminum structure with electrical cabinet and CE-marked components, designed to ensure safe, continuous operation adapted to the requirements of the production line.
Technology used:
- 15 kW electric steam generator NGV-1700, with all components in contact with water in stainless steel AISI-304.
- Autonomous module with 4 ergonomically distributed steaming positions, with safety measures against unintentional activation.
- Siemens Simatic S7-1200 controller with 7″ HMI touch screen for programming, control and visualization of process parameters.
- Synchronization by means of light signals with the rotating wheel: each position indicates to the operator the booty corresponding to the cycle
- 24V DC solenoid valves and automatic drains at each position for condensate recovery
- Individual switch per position to enable or disable according to product to be processed
- Condensate recovery tank DRC-00045 of 45 L in AISI-304
- Aluminum structure, electrical cabinet and components with CE marking
CHALLENGES
We meet customer requirements
Automated synchronized steaming solution with rotary gluing station, designed to improve ergonomics, process control and operational efficiency in the manufacture of safety boots. We achieved the following results:
Total process control: the PLC with touch screen HMI allows to program times, pressures and sequences by product type, as well as to visualize parameters in real time.
Energy and water efficiency: individual position enablement and condensate recovery in the DRC-00045 tank significantly reduce water and electricity consumption.
Synchronization and ergonomics: the light signals integrated with the rotating wheel eliminate positioning errors, improve line cadence and relieve the operator from awkward postures.
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There are no emissions beyond those produced during the electricity production process. Consequently, emissions can be neutral depending on the electricity mix. Electric steam boilers are the present and the future.
Absolutely. In fact, it is recommended to achieve maximum efficiency. There is no problem with remote control as long as it complies with current regulations.
A steam generator is a pressure vessel that, together with the piping network, is subject to regulatory control and complementary technical instructions, according to the regulations published in Royal Decree 809/2021, of September 21. Maintenance is divided into a part that can be easily fulfilled by the owner:
- Know and apply the manufacturer’s instructions regarding use, safety measures, and maintenance.
- Not to put the installation into service or prevent the operation of pressure equipment if the requirements of the Regulation are not met.
- Having at least the following documentation for the pressure equipment while they are installed: Declaration of conformity, manufacturer’s instructions (if applicable), and, if necessary, installation certificate, along with other supporting documentation (such as installation project, record of the last periodic inspection, certifications of equipment repairs or modifications, and any other documentation required by the relevant technical instruction complementary to this regulation). For detailed contents, refer to Annex IV of the regulation. Making this documentation available to the competent authority of the autonomous community and the companies responsible for maintenance, repair, or periodic inspections.
- Use the pressure equipment within its intended operating limits as specified by the manufacturer and take it out of service if it no longer meets the necessary safety requirements.
- Perform maintenance on the installations, pressure equipment, safety accessories, and control devices in accordance with the operating conditions and manufacturer’s instructions, and examine them at least once a year.
- Arranging for the necessary periodic inspections as required by Article 6 of the regulation.
- Having and maintaining an up-to-date record of pressure equipment categories I to IV, as defined in RD 709/2015, of July 24, or equipment similar to these categories according to Article 3.2 of the regulation, as well as their installations.
It is known that by applying heat to water, it transforms into steam at the boiling point and atmospheric pressure. From there, depending on the required saturation degree of steam for its proper application, we need to increase the pressure to obtain a higher temperature. To change the temperature and saturation degree of steam, we always need to modify the pressure.
It is a unit of pressure equivalent to 1 kg/cm2, 0.98 atmospheres, or 14.50 PSI.
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