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system guaranteeing electrical quality-security-reliability. |
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In Mondragon Sistemas, we have developed a solution to avoid energetic
problems that can cause important damages in a lot of companies.
What is the problem?
Very brief micro-interruptions can occur in the supply given by the
network. They can cause failures in the actioners that control critical
industrial processes, with their consequent important economic losses,
but also with losses in terms of images and of human relations. This
is why we started studying the problem to find out a solution.
To explain the situation in a more global way, the energy supplier
must deliver energy according to the EN 50160 standard, but most of
the companies are not sure their supplier is reliably doing so. Moreover,
the machines themselves can emit perturbations that provoke distorsions
in the network. Often, the company has difficulties to define where
the problem is.
The solution Mondragon Sistemas has developed is based on an applicative
software.
Our solution analyses the reason of the perturbation, then provides
us with information to build up a solution. We deliver full guarantee
over the defined solution.
We have developed a software that enables simulation of different
perturbations of the energy under different casuistics of machinery
and of industrial processes. We can thereby give treatment to an important
volume of data that are associated to various electric variables,
understand different casuistics of processes and of machines and measure
data under the different practical behaviours.
Finally, the quality of electric energy is evaluated in function of
the perturbation levels in the electric energy supply network.Tension
drops, overvoltages, tension and power historics, harmonics, wave
forms, instantaneous measurements,..., a great number of data can
be managed. The internal sources of perturbations of the company are
analysed in function of the typology of each industry and of the associated
machinery. We use an Oracle data base for this purpose.Decisional
software
The system contains a decisional software program for assistance in
decision making process. It uses the criteria and the rules that have
been established to give solution to each particular problem.
Moreover, data can be visualised; the system can interpretate the
performed treatment, and verify its accordance to the EN 50160 standard,
its accordance to other specific criteria of the software program.
It finally presents the solution.
What the company wants is to solve the matter in a professional way.
We deliver a technical solution using the latest technologies available
relarted to electric energy quality .
RTS ( Ride Trough System ) tension compensation systems for alternative
current variable speed actioners are mainly used , to keep on supplying
when there is a failure on the network.
Ultracapacities systems,flywheel systems, SMES systems ( Superconducting
Magnetic Energy Storage) are technologies currently used for energy
storage purposes.
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| New offices in Aretxabaleta
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Our team in Aretxabaleta has inaugurated new offices located at 100
meters from their former location.
The new settlement is more in accordance with the importance of our
agency in Aretxabaleta and brings a unique location to the activities,
among highly advanced technological companies.
Tanto el teléfono como el fax y el mail son las mismos, mientras
que la dirección es Mondragón Sistemas, Pol Basabe Edif.
6, 20 500 Aretxabaleta.
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| Mondragon Sistemas
builds up the control system for Fagor Ederlan's central warehouse
unit |
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Via implantation of identification and radio-frequency systems.
MMondragon Sistemas, in its activity
of improvement of production processes and of logistics, has automatised
the central warehouse unit of Fagor Ederlan in Vitoria, a storage
capacity of 10.000m_ receiving products with a very high rotation
rate.
The used technology combines identification systems ( basically barcode
) with radio-frequency, for data wireless transportation and thereby
error elimination.
These errors are avoided using barcodes identification systems and
performing reading with various types of readers such as pistols,...,
that are handled by the user until the area of location of the product,
avoiding any manual intervention on stock control.
Barcode systems, readers, printers, radio-frequency end terminals,
PDAs, are used in the defined solution. The implanted systems in this
application are Intermec, for which Mondragon Sistemas is Solution
Partner.
The functions the system performs are the following: reception of
all the finished product from the plant, management of storage surface
and id-location, preparation of shipments to customers, returns to
plant, quality management system with capacity to isolate and block
any storage area, information about stock availabilities and state
of quality, integration to the SAP R3 back-office system.
The project had to be carried out in a very short delay, and the customer
made significant progress and benefits in warehouse management. These
factors lead us to organize a seminar in Otalora attended by 31 Directors
of Production and Warehousing, with lectures given by the responsibles
for the project. Product flux management experiences in other fields
of activities were also shown, together with mobile terminal experiences.
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| Information
system for Renfe ( Spanish Railways Company) |
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The Santander-Reinosa omnibus railway line is equipped with an interphony
and megaphony system developed by Enyca, Department of Mondragon Sistemas.
This experimental system is going to be extended to the 26 railways
stations of the line. |
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This line has
received our SIVIFE (Sistema de Información y Explotación
Ferroviaria- Railway Exploitation and Information System) system that
operates via HDSL, optical fiber, and wireless networks. Financing
sources have been found in the CDTI.
This system, exclusively developed for railway lines, offers centralised
systems of information to passengers, that include interphony devices,
automatic megaphony, information screens about departure/arrival times,
CCTV in the different railways stations, ie in the different elements
constitutive of a railway line and of its periphery.
The extension project planned by Renfe also includes four totally
new stations that will complete the existing line and that will also
be equipped like the other existing stations with SIVIFE.
The two critical issues of the project are the very short delay for
its consecution and its integration to the existing megaphony and
interphony network.
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| Mondragon
Sistemas carries out the automation of a levelling line in Poland |
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Mondragon Sistemas has finalised the automation of a levelling under
tension line in Huta Aluminium Konin, the only Polish Company that
produces aluminium, a Company of the Impexmetal Group, located in
the city of Konin, Poland.
It is a levelling under tension line with the ability of off-line
autonomous work, with a u on-line system connected to the degreasing
line, that existed prior to the project.
The project took place in 2001 and an extension was ordered in 2002
and finalised in September 2002.
The line levels aluminium strips with the objective of obtention of
a good levelled surface, works with winds from 0,08 mm to 1,5 mm.
The complexity to solve is to obtain an elongation rate of 0.15% to
1.5% due to a tension generated between two fixed points, the whole
operation respecting a quality of levelled surface at the exit of
the line with a line speed that can soar up to 200 meters per minute.
The aluminium processed is destinated to packaging, automotive industry,
windows construction,...The new production features have enabled Huta
Aluminium Konin improve significantly quality and outputs: the process
is now continuous in the levelling and in the degreasing phases, and
the product coming out presents a better state of surface.
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| Quality
control and traceability system for cranks production in the automotive
industry. |
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Renault Industrial Vehicles, RVI.
Situation before the project
RVI manufactures its cranks through a process in which they undergo
successive phases and operations of mechanisation on a line equipped
with several centers of mechanisation. In order to improve
the control of the process, Mondragon Sistemas has developed an
intelligent system of control and traceability that has been installed
and gives excellent results.
The solution
The solution proposed by Mondragon Sistemas performs at each phase
of the process:
-unitary control of the manufactured products, control of the realised
production.
-control of historics of global results per reference of product.
-statistical control of the encountered variations per parameter
and per produced unit.
And for the whole process
-control of the stability of the process
-control of the output of the line
-re-calibration of the system
The system allows the following parameterizations per phase:
- measurement conditions of each parameter for each reference
- tolerance forks for each parameter of each reference
- attributes to verify per reference and corresponding acceptance
limits.
Architecture
The architecture of the solution is the following:
-A control PC, at the exit of each phase, that controls and reads
the various sensors and their corresponding variables, plus a scanner
that identifies each mechanised unit.
-A final control PC.
-An Ethernet network for the ten installed PCs.
-On the same network, a data server for the software program equipped
with a data base, that enables exploration of all the data of the
factory from a General Management PC, and the consequent file printing.
Benefits
The obtained main benefits are:
.immediate correction of distorsions occurring in each phase.
.Information in real time about problems occurring on a line, generating
immediate maintenance action plans.
.Improvement in productivity, elimination of irrecuperable product.
.Real implantation of a system of continuous improvement of the
process, by systematic use made of the statistical control of the
realised measurements to the whole production, that gives knowledge
about errors and about the consequences of the realised adjustments.
.Accurate , simple and immediate knowledge about the traceability
of a product.
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| Mondragon
Sistemas takes a 17 % sharehold participation in the Finno-Swedish
WebRay company. |
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Webray is a leader on the QCS market in the paper industry.
Mondragon Sistemas has taken a 17% shareholder participation in
this company.
It strengthens Mondragon Sistemas' position in the paper industry,
bringing full coverage over automation systems offer destinated to
this market, from traceability to QCS, through the existing offer
of automated systems and information systems for paper production.
It will enable Mondragon Sistemas launch new products towards the
paper production industry and obtain a preferential international
position. Europe, Asia and South America are the main target markets.
WebRay
WebRay was born in 1991, and focuses its activities on quality measurement
systems for the paper industry. It exports towards 15 countries for
a sales turn-over of 12 millions of euros .
Its star product is QCS, an on-line quality data control system for
paper production. Basic weight, moisture, caliper, ash and other features
are controlled.
Alliance for the paper industry
The experience developed by Mondragon Sistemas in the paper industry
has lead them to integrate an Alliance for the improvement of productivity
based on the generated information at the level of the process of
production of paper.
Bapco, Gorostidi, Brunnscheiler, Papelera del Aralar, Escuela Papelera
de Tolosa, Predicsa and Robotiker, make also part of this Alliance,
that is supported by the Knowledge Management Cluster and the Basque
Government.
In a first step, the Sicomap project will be developed. It aims at
improvement of the production process of paper. Mondragon Sistemas
will bring its Tracelia MES product experience in the field of paper,
with all the on-line information about production and planning control
and all traceability data of the product in the productionphase.
Improvements of around 50 % in production outputs are expected from
the application of derivated systems coming from the Sicomap project.
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| Mondragon Sistemas automatizes
warehousing in Iparlat. |
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The installed system automatizes warehousing and shipments from factories
integrating them to the SAP back-office system. Mondragon
Sistemas has conceived and developed a new system of control of
shipments and warehousing for the two production plants and associated
warehousing units of Renedo (Cantabria) and Urnieta (Gipuzkoa).
The system is based on radio-frequency end terminals technology
and is integrated to the SAP back-office management system of the
company.
Its objective is to send the appropriate goods eliminating errors
in order to guarantee an invoicing corresponding to the content
of the shipped load. As a consequence, productivity increases, allowing
fast ROI.
Exact knowledge of the realised shipments, of stock in real time,
and of the logistic chain at the level of production batches is
obtained.
Iparlat, from a single end computer with SAP, sends the orders of
shipment to identified end terminals for their former execution.
The realised transactions and operations informations are sent to
the transactions server , then to the central server. Both production
plants are connected to a single Oracle data base.
Once the orders are executed, the information corresponding to the
realised shipments, together with the traceability data of the product,
data about the responsible for load and destination, are integrated
in a single data base that hendles all the warehousing areas. It
sends the packaging list of each order of shipment to SAP for the
printing of the exact corresponding order of shipment form.
This shipment control reduces errors, emits exact order of shipment,
assures shipment control, assures production traceability via a
barcode labelling, and controls production batches that are in quarantine
and their isolation until quality control release, always under
FIFO modality.
Mondragon Sistemas offers broad experience in automation of warehousing
systems using radio-frequency. Automation, Industrial Informatics
and Telecommunications are its fields of activities, with ninety
two people working, engineers for the main part, with great experience
of work in international environments.
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| Electric compatibility
tests are passed |
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Mondragon Sistemas has
sent all the control and power equipment of a cut to length line destinated
to be installed in a Belgium company to undergo EMC electric compatibility
tests.
Within its policy
of quality and of improvement in industrial automation, Mondragon
Sistemas submitted its own control and power equipments to EMC electromagnetic
compatibility tests, that were passed without any problem.
The tests were undertaken for the control and power equipment of
a cut to length line conceived for a Belgium company, in accordance
with the quality standards of Mondragon Sistemas that fulfill the
ISO 9001 standards.
The performed tests were:
- Measurements of Radio-Electric Conducted Emissions
EN61800-3. With limits for I>100 A
-Electrostatic Discharge Tests Immunity
EN 61000-4-2 (1995 )
-Conducted RF Immunity
EN61000-4-6 (1996 )
-Electrical Fast Transient Immunity
EN61000-4-4 (1995 )
The Low Voltage Laboratories of Labein, homologated technological
center integrated in Tecnalia, made charge of the tests.
In its final report, it indicated that "the system undergoing
the procedure was tested in functioning with all its elements interconnected.
The functioning was carried out via simulations of real operations
( cut, uncoiling of the strips,...) controlled by the desk included
in the system and performed by the means of the drives of the various
motors connected to the power cabinet...".
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