Controls
Sly Process Systems offers a wide variety of both Machine Controllers and Custom Configured Controls Systems.
Machine Controllers - Almost all of our standard product offerings are controlled by an “off-the-shelf” American made PLC, complete with an integral operator interface. The vast majority of these products employ a color touch screen interface with standard Ethernet communication built in. Unlike many competitors, we DO NOT employ proprietary hardware components that may only be purchased or serviced by us. ALL of our products utilize components that have a worldwide distribution network. Programming software for our standard PLC control offerings is FREE and can be downloaded from an internet website. Standard software is intuitive with a menu driven graphical interface utilized in most instances. Several troubleshooting and production monitoring aids are standard such as trending for all process variables, alarm and event logs, and maintenance troubleshooting screens. Remote monitoring and troubleshooting capabilities are available via an Ethernet network or cellular link. Collected process information can be stored on a memory card and manually downloaded or transferred via Ethernet to a spreadsheet for analysis and recordkeeping. Numerous optional networking and communication protocols are available.
Most of our standard product PLC controls can be utilized as retrofits for outdated controllers on competitor’s equipment. Among our standard PLC based, color touch screen/Ethernet equipped machine controllers include the following. Any of these may be retrofitted as replacements on corresponding competitor’s equipment:
Twin Bed Desiccant Dryer Controllers – These units are currently offered in two levels of sophistication:
- Our Stage I Dryer Controller is applicable to most twin tower (dual bed) desiccant dryers with separate regeneration and process air blowers and heaters. It will interface with most dew point sensors that have a 4-20 mA output, and relies on pressure and flow switches, along with thermocouple inputs (typically found on most dryers) for monitoring and control.
- The Stage II Dryer Controller is utilized with optional analog pressure and flow sensors and thermocouple inputs to convert an outdated but functioning dryer for state-of-the-art operation, control, and monitoring.
By adding additional hardware, most existing twin tower dryers can be equipped for dry air bed cooling and regeneration heat recovery which not only reduces energy consumption, but improves regeneration and drying efficiency.
Gravimetric Continuous Batch Blender Controller are typically utilized for control of batch blenders utilized in plastics processing applications where colorants, additives, and/or regrind is blended with virgin resin prior to an extrusion, injection molding, or similar process. However, the Sly Process Systems blender controller may be utilized to control any multi-ingredient blending process that relies on ingredients being fed from surge hoppers equipped with gates, screw, or vibratory feeders into a single weigh hopper and then discharged to a separate mixer for mixing and discharge to the process. Our standard color touch screen controller will handle up to 6 ingredients, with up to 12 ingredients as an option. Features include multiple formula storage, batch ingredient weight storage, total usage of ingredients and throughput totalization. Standard control outputs are 24 VDC with 110 VAC as an option.
Vacuum Pressure Rail Unloader Controller – The Sly Process Systems rail unloader controller can be applied to ANY vacuum-pressure (pull-push) pneumatic conveying application utilizing either a single PD blower or separate vacuum and pressure blowers. The standard controller will handle up to 4 destinations (typically silos), with 8 or more destination points as options. The controller accepts pressure and vacuum inputs from (optional) 4-20 mA transmitters for control and alarm. Standard inputs include vacuum receiver (or cyclone) high level sensor, and silo high level sensors from the destination silos or bins. Outputs include control for a vacuum receiver filter cleaning sequencer and for bin vent activation on the destination silos. Standard output control voltages are 24 VDC and 110 VAC.
Vacuum Sequence Controller for Vacuum Batch Conveying Applications – A vacuum sequence conveying system utilizes a single vacuum blower connected to one or more vacuum receivers to convey material from a single point or multiple points to a single destination or multiple destinations. Material is intermittently conveyed and discharged. During the convey cycle, the vacuum blower is connected to the appropriate vacuum receiver through a series of “Station Tee Valves”. At the end of the convey cycle the receiver is discharged by gravity by releasing the vacuum and allowing the receiver to empty. The vacuum release is typically handled by a “Vacuum Breaker Valve” located at the blower inlet. The Vacuum Breaker Valve opens to atmosphere, breaking the vacuum to the receiver while the blower continues to run. Based on a “First In – First Out” algorithm, destination points requiring material (typically determined by a level sensor) are placed in a “Queue”. The Vacuum Sequence Controller alternates the conveying/discharge cycles among the destination receivers in order to satisfy the demand for material at each point. Multiple vacuum blowers and multiple receivers may be combined to offer a cost effective system with the flexibility to allow ANY vacuum receiver to be connected via control logic to ANY vacuum blower. Sly Process Systems offers PLC based Vacuum Sequence Controllers in a number of standard configurations ranging from one vacuum blower and three destination receivers, to 12 vacuum blowers and 48 vacuum receivers. Multiple controllers can be networked together to control a practically unlimited number of vacuum blowers and receivers. Control is also provided for conveying line purge valves, solenoid actuated receiver discharge gates, and pulse jet cleaning in-line filters ahead of the vacuum blowers. Control voltages are available in 24 VDC and 110 VAC.
Upon demand, any of our standard machine controllers can be provided in alternate PLC platforms such as Allen-Bradley™ and Siemens™.
Custom Configured Controls Systems – In addition to our standard Machine Controllers, custom configured bulk material handling and processing systems furnished by Sly Process Systems can be supplied with user friendly PLC based controls. Each custom controls package is engineered for the application intended. The PLC platform utilized will be selected based on the application requirements, overall cost, and the end user’s plant standard as required.
Numerous operator interface options are available ranging from simple text or graphic touch screens to sophisticated computer based interfaces utilizing WonderWare™.
Motor Control Centers are also available ranging from simple enclosed local pushbutton operated motor starters with integrated circuit and motor protection, to large Motor Control Centers involving VFD control of multiple motors and devices.
