Flexible HMI for Extruder Control
More Flexibility. Less Engineering.
Coperion relies on a flexible HMI architecture with atvise® for its CSpro extruder control system: Parameterizable machine control reduces software engineering effort and enables maximum scalability.
Application: Controller for Twin-Screw Extruders
Coperion uses atvise® in the CSpro controller of its twin-screw extruders. These machines are used wherever plastics, compounds, and other materials are continuously processed, mixed, modified, or manufactured. Thanks to their modular design and high process flexibility, Coperion twin-screw extruders are suitable for a wide range of applications, such as in the plastics industry, the chemical industry, plastics recycling, and for specialized applications with high demands on product quality and process reliability.
Within the CSpro controller atvise® handles the visualization and operation of all machine functions. Operators can monitor process values, manage recipes, configure machine parameters, and use diagnostics and alarm functions. The consistently parameterizable control concept allows different machine configurations to be implemented without additional programming effort. New functions and machine options can be efficiently integrated into the existing platform, resulting in a standardized yet flexibly expandable control solution.
Coperion is a leading global provider of machine and plant solutions for the plastics, chemical, food, and further process industries. Among other things the company develops twin-screw extruders and complete compounding lines, establishing a connection between process engineering and modern automation. Coperion's control systems offer extensive functions such as production data acquisition, recipe management, analysis, and integration into industrial communication environments.
CaderaDesign is a design and development company specializing in industrial products, with a focus on user experience, HMI, industrial design, and digital product development. The company supports machine and plant manufacturers in developing intuitive operating concepts. In doing so CaderaDesign combines user-centered design with a deep technical understanding to develop high-performance and future-proof operating solutions for industrial applications.
Initial Situation: Transmission of an Existing Concept to New Technology
Coperion has equipped its proven CSpro extruder control system with a new graphical user interface. The previous generation of CSpro already used atvise® as the basis for machine operation. The core task of the relaunch was to transition the existing operating concept to the new design and operating concept from CaderaDesign while further developing it technologically. The already established concept of a configurable machine was to be implemented in a modern, high-performance user interface based on atvise® and flexibly expanded to meet future requirements.
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The open architecture of atvise® was a key factor in this success.
states Nico Arbter, development engineer at Coperion, describing the platform's significance.
atvise® Enables Customization Without In-House Development
A particular strength of atvise® lies in the connection of product standards and customization capabilities. For Coperion this meant that the basic functions of an industrial HMI platform are available while extensive options for customization and expansion remain intact.
Unlike a completely in-house development basic functions such as data communication, processing, and visualization mechanisms do not need to be built from scratch. Instead the engineering team can focus on the actual machine requirements.
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It was precisely this flexibility of atvise® that made it possible to implement the design specifications developed jointly with CaderaDesign to the greatest extent possible while efficiently maintaining the HMI architecture. As an HMI tool atvise® not only provided the necessary creative freedom to implement the user interface concept but also enabled extensive automation of the software engineering process. This combination of high design freedom and automated engineering was a decisive advantage for Coperion.
explains Nico Arbter.
Parameterization Replaces Individual Machine Programming
The key feature of the solution is that each machine variant can be parameterized directly via the HMI web interface. In the background a unified base project serves as the technical foundation. This allows Coperion commissioning personnel to configure the respective machine via the user interface without having to create a separate engineering project for each machine variant. The required operating and diagnostic functions are automatically generated based on the existing machine parameters.
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Views and functions are automatically generated in the background based on the parameter settings. For most projects this eliminates the need for additional software engineering effort. New machine variants can thus be efficiently configured and commissioned without having to redevelop the user interface for each project.
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Web Based Architecture Opens up New Possibilities
Thanks to atvise® web based technology the user interface is not exclusively tied to a local operator terminal. The control architecture thus supports modern requirements regarding digitalization and plant networking. Coperion uses functions such as web access, data provision, and standardized communication to flexibly integrate the combination of Programmable Logic Controller (PLC) and HMI into modern production environments.
The CSpro controller offers extensive functions for production data acquisition, recipe management, alarm management, and analysis. In addition, the architecture enables integration into higher-level production environments via standardized communication mechanisms.
Modular HMI Structure Supports Complex Machines
A further technical advantage lies in the modular structure of the user interface. The concept was designed so that information can be provided as needed.
Operating complex twin-screw extruders requires access to numerous process parameters such as temperature, pressure, or speed. The technical challenge lies in making this information available in a structured manner without unnecessarily complicating the operation.
Through the combination of modular functions and flexible HMI architecture the GUI can be adapted to different machine types and user requirements. The information structure developed by CaderaDesign supports the efficient use of the machine's extensive functions.
Future-Proofing Through Upgradeability
A key advantage of the solution becomes apparent throughout the entire life cycle of the machines. The current HMI generation is backward-compatible with earlier versions. This allows the controllers of existing plants to be modernized even after many years.
Platform independence also supports long-term use. Migrations between different generations of operating systems have been implemented without fundamental changes. For Coperion this means a sustainable control platform that both meets current requirements and enables future expansions.
Efficient Implementation Using Existing Know-How
Since Coperion already had extensive experience with atvise® prior to the introduction of the new CSpro Graphical Interface the project could be implemented largely independently. For specific technical issues the team drew on the expertise of the Bachmann Visutec application team on an ad hoc basis to achieve targeted acceleration in implementation.
During a joint kickoff meeting in Eisenstadt the technical approach and key issues were coordinated. The joint work originally planned for two days was completed after just one day as the main issues had been resolved.
summarizes Nico Arbter of Coperion.
Conclusion: atvise® Establishes a Connection Between Standardization and Maximum Flexibility
The Coperion project demonstrates how modern HMI technology can reduce software engineering efforts in mechanical engineering. atvise® offers an industrial platform with all necessary basic functions while also providing the freedom to implement custom machine designs.
A particularly challenging aspect was the connection of CaderaDesign's high design requirements with extensive automation of the software engineering process. With atvise® both requirements could be met to the necessary extent. The combination of design freedom and automated software engineering creates a flexible and future-proof solution for different machine variants.