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KGS Based Control for Parking Brake Cable Manufacturing System

KGS Based Control for Parking Brake Cable Manufacturing System

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Published by ijcsis
In today’s competitive production environment, process industries, demand a totally integrated control and optimization solution that can increase productivity, reliability and quality while minimizing cost. Automation is a step beyond mechanization. For automation of production plant either centralized or distributed control system are used. There are standardized approaches and standard hardware & software available worldwide as per the requirement. Investment in process control system is also an important factor in improving product quality and
lowering production cost while providing a competitive edge to industries, which has forced to others to improve their process control technology. Various aspects of centralized and distributed digital control and its pros and cons have been studied. Here an attempt is made to overcome the disadvantages of above system to improve efficiency as well as profit level by going into minute details from root to top level i.e. on line operator up to management or
supervisor level, the system named as KGS i.e. Kaleidoscopic Governing systems. Paper presents, the technical
viability of ‘KGS’ system how it is efficient in various ways to optimize output, improve profit margin and reliable
for output prediction in the operation of manufacturing of PBC Cable which is used in automobile sector.
In today’s competitive production environment, process industries, demand a totally integrated control and optimization solution that can increase productivity, reliability and quality while minimizing cost. Automation is a step beyond mechanization. For automation of production plant either centralized or distributed control system are used. There are standardized approaches and standard hardware & software available worldwide as per the requirement. Investment in process control system is also an important factor in improving product quality and
lowering production cost while providing a competitive edge to industries, which has forced to others to improve their process control technology. Various aspects of centralized and distributed digital control and its pros and cons have been studied. Here an attempt is made to overcome the disadvantages of above system to improve efficiency as well as profit level by going into minute details from root to top level i.e. on line operator up to management or
supervisor level, the system named as KGS i.e. Kaleidoscopic Governing systems. Paper presents, the technical
viability of ‘KGS’ system how it is efficient in various ways to optimize output, improve profit margin and reliable
for output prediction in the operation of manufacturing of PBC Cable which is used in automobile sector.

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Published by: ijcsis on Jul 07, 2011
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KGS BASED CONTROL FOR PARKING BRAKE CABLEMANUFACTURING SYSTEM
 
*Geeta Khare & **Dr. R.S. Prasad
Abstract:
In today’s competitive productionenvironment, process industries, demand atotally integrated control and optimizationsolution that can increase productivity,reliability and quality while minimizingcost. Automation is a step beyondmechanization. For automation of production plant either centralized ordistributed control system are used. Thereare standardized approaches and standardhardware & software available worldwideas per the requirement. Investment inprocess control system is also an importantfactor in improving product quality andlowering production cost while providing acompetitive edge to industries, which hasforced to others to improve their processcontrol technology. Various aspects of centralized and distributed digital controland its pros and cons have been studied.Here an attempt is made to overcome thedisadvantages of above system to improveefficiency as well as profit level by goinginto minute details from root to top leveli.e. on line operator up to management orsupervisor level, the system named asKGS i.e. Kaleidoscopic Governingsystems. Paper presents, the technicalviability of ‘KGS’ system how it isefficient in various ways to optimizeoutput, improve profit margin and reliablefor output prediction in the operation of manufacturing of PBC Cable which isused in automobile sector.
Keywords:
- Distributed Controlsystems, KGS, Conduit, Abutment, PBC
*Geeta Khare, Principal, S.S.J.P, Asangaon, email id:-geetaharshu@gmail.com**Dr.R.S.Prasad, Professor & Director, R.R.I.M.T., Lucknow
(IJCSIS) International Journal of Computer Science and Information Security,Vol. 9, No. 6, June 2011240http://sites.google.com/site/ijcsis/ISSN 1947-5500
 
 KGS BASED CONTROL FOR PARKING BRAKE CABLE MANUFACTURING SYSTEM 
Introduction:
Previously, industrial plant equipment,such as pumps, motors and pneumatics,was reliable and kept water flowing ormachines opening, having no intelligenceand generally no interface apart from someminimal manual controls. As technologydeveloped, sensors and actuators wereadded and closed loop control systemscreated, so simple interfaces informed theoperator about temperature or revolutionsper minute, whilst data loggers andrecorders provided history on graph paper.Automation is a step beyondmechanization, provided human operatorswith machinery to assist them with themuscular requirement of work, automationgreatly decreases the need for humansensory and mental requirements as well.Centralization process control combinedwith increased mechanization has resultedin improve productivity.For automation of production plant eithercentralized or distributed control systemare used. Automation plays an increasinglyimportant role in the world economy. Ithas a notable impact in a wide range of industries beyond manufacturing. Processsystem as a part of full plant automationshould be designed to improve productionefficiency, operator efficiency and assetoptimization. The ability to control theprocess with accuracy, flexibility and highavailability is more important than ever toincreasing quality, productivity andproviding a sustainable competitiveadvantage. It enables distributed controlapplications and devices that delivermaximum reliability, survivability andresponsiveness.The DCS largely came about due toincrease availability of micro computersand the proliferation of microprocessor inthe world of process control. In theindustry reliable process are crucialsuccess. To stay competitive a plant mustfunction smoothly and efficiently at alltimes, delivering the best possible returnon investment at the lowest possible costs.The use of DCS is becoming popular anduseful to control complex process in theindustry that involves multiple variablesand control loops. EMERSON,YOKOGAWA, FOXPRO andHONEYWELL have widely used DCSsystem in the industrial process forautomatic control. The DCS acts as asignificant and critical role in humansupervisory control of automated plant
(IJCSIS) International Journal of Computer Science and Information Security,Vol. 9, No. 6, June 2011241http://sites.google.com/site/ijcsis/ISSN 1947-5500
 
applied in diverse complex industries suchas power plant, refinery, chemicals,pipeline and manufacturing and manymore. There are standardized approachesand standard hardware & softwareavailable worldwide as per therequirement. Various aspects of centralized and distributed digital controland its pros and cons have been studiedand disadvantages of these systems areimproved in KGS system.
KGS System
:The advancement in embedded technologyis used to take care of local parameters. Itgives full facility to local operator tointeract with the process using keyboard &LCD display. The settable alarm method& alert message reduce operating skills &breakdown time. It has enough memory totake care of data. The data memory will berefreshed every time & data of interest of management will be sent to a pc throughsimple Ethernet data highway. The pcmemory if not enough to take care of alldata of interest then it can be transferred tospecial data storage element. The data of interest of respective department is alsostored at the PC of that department. Wehave provided simple embedded controllerat each control section which not onlytakes care of its own section to optimizesystem but at the same time communicateswith supervisory pc and alerts for presentstatus by giving data. This gives benefitsin following way.
 
It ensures simple and fast engineering andno probability of programming errors andensures fast commissioning as all the cardsof compatible.
 
It ensures a significant boost inproductivity throughout the entire lifecycle of the plant.
 
It is designed to provide higher plantavailability and productivity.
 
Reduce plant down times as well asoperating and maintenance cost as onlycard replacement in worst case.
 
No skilled man power is required so allprocess control components reduce downtime in the case of problem or other eventsand minimize production losses.
 
There is no single point of decisionmaking and therefore there is no singlepoint of failure.
 
Increased reliability with decreasedcommunication costs.
 
DCS delivers the needed response time,and enhances system survivabilityincreases reliability and lower cost.
 
A simple PC can acquire data for MISpurposes.
 
Date transparency up to the manageriallevel in real time.
(IJCSIS) International Journal of Computer Science and Information Security,Vol. 9, No. 6, June 2011242http://sites.google.com/site/ijcsis/ISSN 1947-5500

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