ACSI combines the latest technology, with our knowledge of a specific application, to create an overall best fit custom solution for manufacturers.
Model Based Control
Process upsets within a manufacturing environment can impact both product output and quality. Conventional methods of process control, such as PID, can require operator intervention in order for the system to adapt to these different variables. To help minimize operator intervention, it may be beneficial to implement a model based controller (MPC). A model based controller will make adjustments by utilizing its programmed model of the process, and in turn, will achieve better control without loop tuning. In addition to reacting more efficiently to changes, ACSI’s Model Predictive Control (MPC) models feedforward inputs and updates control actions to quickly stabilize any temperature variation. The model makes necessary changes before the upset reaches the local zone, and in most cases, can completely eliminate the upset before it is sensed by the zone.
Process Mapping identifies opportunities for the customer to reduce key cost structures such as materials, energy, human resources, and maintenance. For each control segment, a detailed analysis will identify key metrics (parameters) for control, key cost factors for measurement and reporting (materials and energy), key factors for quality measurement and reporting, and identify manual Operator actions & the reasons for them. A detailed recommendation, that will meet current and future needs, as identified in the process map, is then provided to the customer.
PLC-resident flexible batching algorithms allow for the creation and modification of batch sequences (recipes) through the HMI interface without reprogramming at the PLC level. These advanced predictive adaptive control algorithms improve accuracy and throughput while decreasing process variability. Our batch control systems incorporate a proprietary Automatic Preact Adjustment Algorithm for weighing control. The algorithm takes the guesswork out of the process by recording and analyzing weighing performance. Engineers can quickly create or change recipe procedures and formulas leading to increased operational efficiency while effectively managing multi-product batch operations.
Real-Time SPC Control
Bring an additional level of control to your process with ACSI’s Real-Time SPC. Real Time SPC Control is based on the application of statistics to real-time process control. This strategy is successful with long deadtime, multivariable, applications where traditional methods (PID) have failed. Unlike traditional PID, SPC statistically determines whether the process is out of control prior to taking action. When a control adjustment is required, the system makes a single significant change, then analyzes the response. This eliminates constant changes that lead to process cycling.
As an integrator of information and control system solutions, ACSI engineers, based in the United States and Europe, are able to provide customers with quality technical engineering, system design, factory acceptance, installation supervision, commissioning services, and training. ACSI currently services customers located in over 40 different countries.