DEVELOPING AN EXTRUDER MACHINE OPERATING SYSTEM THROUGH PLC PROGRAMMING WITH HMI DESIGN TO ENHANCE MACHINE OUTPUT AND OVERALL EQUIPMENT EFFECTIVENESS (OEE)

Designing a state-of-the-art PLC-based extrusion machine with a user-friendly HMI ensures seamless operation, enhancing Overall Equipment Effectiveness (OEE). This project focuses on automating an extrusion system with advanced technologies for optimized functionality and reliability. The architecture includes sophisticated components to boost productivity and product quality. Key aspects involve orderly control and synchronization of the extruder motor, feeder motor, lubrication pump, and vacuum pump for consistent performance with precise temperate profile. A significant innovation is the centralized blower system for machine temperature profile analysis and control, replacing individual controllers to enhance thermal management efficiency and ensure uniform temperature distribution. A high-low temperature alarm system alerts operators to deviations, maintaining process stability. Real-time data on current (Amps) and frequency (Hz) is displayed on the HMI from the inverter for monitoring and diagnostics. The system also features machine downline controlling capabilities for efficient management of downstream processes. Collectively, these innovations create a robust, efficient, and user-friendly extrusion machine that enhances OEE and product quality.