CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES
Automation upgrade improves brick quality
A local clay brick manufacturer has upgraded one of its brickmaking plants with assistance from drive and con- trol technology specialist SEW-EURODRIVE. Using ad- vanced digital solutions based on Maxolution for factory automation, a new, optimised plant has been installed for the production of high quality rustic face bricks. “The new plant, which is expected to produce 100 million bricks per year, was built on the back of growth in the local construction industry, which, going forward, is seen as a key sector for South Africa’s economic rejuve- nation and much-needed job creation. “Our client is experiencing significant domestic de- mand and exporting its products into Africa,” says SEW-EURODRIVE Field Service Technician, Juandre La Cock. The rustication process used to make the textured face bricks is a masonry technique that involves cham- fering the edges of a brick to allow the mortar joints to be set back, and texturing face surfaces using a rough- ened roller with blades. The process follows the extrusion of the clay to form the cross-section required, with the bricks being rusticated on three sides, including the front face and both ends. The existing, basic rustication system was producing an unacceptable amount of waste and this led the brick maker, a longstanding client, to seek assistance from SEW-EURODRIVE. “With the introduction of an automat- ed solution we were able to reduce wastage significantly. This has resulted in the brick maker placing an order for another three rustication systems for installation at other operations in its portfolio,” says La Cock. Describing how the problem was solved, he explains that, to produce consistently patterned surface textures, the brick manufacturer needed to be able to vary the speed of the rustication process, to run more slowly or faster according to the viscosity of the clay. The drive units for the rollers also needed to enable the rustication process to match the line speed of the extruder. The solution comprised three servo motors with indus- trial gear units between each, to enable the drive speeds to be changed electronically using SEW MOVI-PLC con-
troller software. Automatic synchronisation of the speeds, varied to match the specific clay conditions and texturing requirements, resulted in a continuous operation produc- ing consistently textured high quality bricks. The automated rustication system was commissioned within a standard delivery time of four to six weeks. The equipment was built in Cape Town at SEW-EURODRIVE’s facility in Montague Gardens. Programming took place at SEW-EURODRIVE’s offices in Aeroton, Johannesburg, where most of the equipment was pre-commissioned to limit downtime and loss of production. As a result, the time required for on-site commissioning of the system was reduced to between two and three days. In addition, the client was supplied with a Drive Operating Panel which enables users to interface with the MOVI-PLC and change the settings as needed, to change over to a new face brick style, for example. As soon as the settings are saved, the line can again be started to produce the modified bricks continuously. Primed for service Most of the equipment installed at the brick manufac- turing operation, from gear units to conveyor belts, is supplied by SEW-EURODRIVE. “As well as our effec- tive solutions, it is our high standards of service that see this client returning time and again,” says Service HOD, Eben Pretorius. SEW-EURODRIVE knows that the need for an ac- celerated turnaround time on service or maintenance is critical for manufacturers, as every minute an opera- tion is left standing idle equates to loss of production. “We pride ourselves on our after-sales support, which includes a 24-hour service hotline, a spare parts service, a repair service and an on-site technician service,” says Pretorius. SEW-EURODRIVE technicians can also login remotely to assist clients with software problems and a field service team is on standby 24 hours a day, seven days a week to assist clients on site if the issue cannot be resolved telephonically. The Maxolution solution for factory automation and customised machine systems, offers clients a single source of innovative 4IR-aligned technologies to meet specific applications and needs. With Maxolution for factory automation, clients can balance the need to keep their future options open to react quickly to market requirements. SEW-EURODRIVE supports smart factory designs that comprise new, flexible, adaptable, modular structures. The company is developing its own R200-million smart component assembly factory in Aeroton. The new 26 000 m 2 building will also serve as the company’s South African headquarters, looking after 23 countries. It is scheduled for occupation this year.
The Maxolution solution for factory automation includes servo drives and PLC control software.
For more information contact SEW-EURODRIVE. Visit: www.sew-eurodrive.co.za
8 Electricity + Control MARCH 2022
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