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38 YEARS
EXTRUSION CONTROL SOLUTIONS
RELIABLE
AUTOMATION
AND OPTIMIZATION
OF EXTRUSION
PROCESSES
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PLAST-CONTROL …
A STORY OF SUCCESS
For more than 38 years PLAST-CONTROL has been
automating extrusion processes. From the onset,
we focused on the supply of equipment for blown
film extrusion lines expanding into other extrusion
processes. Today we are the leading manufacturer
in this worldwide market.
Meanwhile, around 30 % from all produced systems are delivered in other areas of the plastic industry: production of cast films, sheets, tubes,
spunbond or injection molding. PLAST-CONTROL
produces exclusively in Germany and delivers
their products worldwide. At the headquarters in
Remscheid more than 22 million euros were generated in the years 2015/2016 with about 85 employees on around 6,000 square meters.
We continuously develop our technologies and offer nowadays complete solutions, among others,
in these areas:
y
Our branch offices and representations ensure a
smooth, global distribution. Around 20,000
PLAST-CONTROL systems were successfully installed and working worldwide.
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Material conveying PRO-VAC (p. 8-10)
Gravimetric weighing PRO-GRAV (p. 5)
Dosing:
continuous PRO-DOS (p. 6)
batch PRO-BATCH (p.7)
Profile automation:
Profile measurement PRO-FIL (p.12)
Profile control PRO-CON u. PRO-JET (p. 13-15)
IBC with width measurement and control
PRO-SONIC, PRO-WIDE (p.17-18)
Laboratory measuring tools PRO-LAB (p.19)
Systems for the central control PCC (p.11)
y Branch offices
y Representations
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AUTOMATION
& QUALITY ASSURANCE
PLAST-CONTROL is the only company in our market which produces all critical components inhouse. This in-depth knowledge of the principles
and hardware gives you, the customer, the chance
to use the process knowledge to the greatest effect.
Complete responsibility of the control technology
and the ability to produce custom made applications offers unrivalled experience and technical
competence.
We can fully automate your extrusion line. Do not
hesitate to contact us!
Our position of being able to design and build
complete control systems without using third party devices and software is unique for the industry.
Advantages:
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Waste reduction and material savings
Fast product changes
Higher outputs
Reproducible products
Reduction of operator faults
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Central Operator Station
Material conveying (vacuum loading) with intelligent control
Gravimetric extrusion control systems, up to 7 dosing units
per extruder or six batch feeders
Thickness profile control, patented air ring technology
PRO-SONIC internal bubble cooling control
PRO-CAGE sizing cage
IBC, internal bubble cooling hardware
On-line profile measurement
Haul-off measurement, haul-off control
Width measurement
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ALL SYSTEMS …
GT3+, GDC-N, ACS
The GT3+ is an economic but yet powerful system
for the gravimetric control of an extrusion line. It
is designed for the control of up to 3 gravimetric
weighing hoppers (e.g. a mono line with a main
hopper and 2 dosing units, or a 3-layer co-ex line
with 3 main hoppers without dosing units).
The GT3+ could also be used when it comes to
pure conveying, width or IBC control – requirements that do not require an extensive visualization.
The complete range of profile representation and
analyzer tools is customizable. The client can
choose between a monitor with key buttons or
with touch screen.
A powerful GDC-N computer grants a fast and efficient control, being the right choice for simple
gravimetric, batch-blending systems or continuous gravimetric dosing systems with up to 15
components. Additional functions such as IBC
and width measurement/control can be integrated.
ACS is the ultimate solution of the product range
and can include all of the functions and features
that PLAST-CONTROL offers in one package. The
operation is simple and very easy to handle with
the large 19”color TFT touch screen display.
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The GDC-N is the compact specialist. The system
handles up to 15 gravimetric weighing hoppers,
temperature control or the profile measurement
and control.
For a simple profile measurement and control system, the GDC-N is the economic solution. Production data is displayed on an easy to read
10.4“ color TFT display with optional touch screen
control for specific functions.
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And there are even more benefits. In addition, all
PLAST-CONTROL systems can handle these functions:
Advantages:
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System GT3+
System GDC-N
System ACS
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Capacitive online gauge measurement
Width measurement and control
IBC control
Material flow control MFC (vacuum loading)
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GRAVIMETRIC
EXTRUDER CONTROL
PRO-GRAV
All our automation principles over the last 38 years
have been based on gravimetric extrusion control. The “loss in weight” principle guarantees
precise measurement of throughput and control
designed for all types of extrusion processes.
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This approach of control is the only suitable principle when it comes to mono- and co-extrusion
applications. This concept works for all continuous extrusion processes. Needed in the process
are a gravimetric weigh hopper frame, a slide
valve and a PC System.
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Hopper frame
GT3+ Screen display
“Loss-in-weight“-principle
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The systems are capable to control the film
weight with a resolution of ± 0.1 % from the average. The system will compensate for deviations
even if the filter from the extruder gets clogged
or a heater band fails. The deviation from the target value will be detected and accordingly corrected so that the film is still produced with the
best quality.
Experience shows that commonly, up to 4 % of
the raw material can be saved. The return of investment is normally 6 to 12 months.
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Advantages:
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In case of co-extrusion lines, the control of layer
thicknesses is done by the adjustment of the individual extruder throughput, matching the target entry. If the production level is increased
through changing the haul off speed, all extruders will simultaneously react and the product
parameters will remain constant even during the
order change phase.
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Raw material savings
No dependence on the bulk density
Fast order change times
Constant product quality
Simple user interface
Customized solutions
Rugged, durable construction
Easy cleaning through the removable hopper
Fast return of investment
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GRAVIMETRIC
CONTINUOUS DOSING
PRO-DOS
Optical, mechanical or functional requirements
for the final product usually require the use of
several types of material per extruder. Various additives ensure as for UV-stability, good printability, good weldability etc. All these additives are
very expensive and must therefore be dosed as
precisely as technically possible.
The best technical solution, is the gravimetric
dosing. In this case, additives are dosed precisely into the main material stream. The assembly
prevents demixing. The measuring is made following the “loss-in-weight“ principle, and the accuracy is of 0.1%.
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Continuous gravimetric dosing
Gravimetric frame with dosing units
Servo-Drive Motor (RCM)
The new MICRO-DOSING units follow the trend to
more components and smaller dosing amounts.
The new units can cover a range from 100 g/h up
to 8 kg/h.
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Fully modular construction allows up to 7 dosing
units plus main material to be fitted to each extruder (including co-extruders). All dosing units
outputs are synchronized with the main hopper
output to guarantee an accurate product recipe.
The latest generation of dosing unit now incorporates a high torque motor delivering a wide
speed range. This minimizes the need for dosing
screw changes. Advanced software control guarantees accurate control from very low to high
output rates.
Advantages:
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Considerable saving of aggregates
Independent from bulk density
Fast product change
No pre-mixed material
Precise dosing of small volumes
Easy operation and simple target entry
Up to 8 components per extruder
No dosing screw changes necessary
Easy cleaning due to removable hoppers
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GRAVIMETRIC
BATCH DOSING
PRO-BATCH
Compared to the continuous dosing, the batch
blender works according to the “gain-in-weight“principle. The material gate opens for a pre-determined time and registers the gain in weight in
the weighing chamber. When the batch is complete, the material is discharged and mixed in the
mixing chamber. The accuracy is of ± 0.3%.
The PLAST-CONTROL batch blenders can be
used off-line as a general purpose blender, online
or on-line with extrusion control. The mixing
hopper itself, works as a gravimetric weighing
hopper in a "loss in weight" process.
The low-cost PRO-BATCH-devices are built for 4 to
6 materials and several types of throughputs.
PB4180
PB4450
PB6150
PB6300
4
4
6
6
Max. output
kg/h
180
450
150
300
Max. output
lbs/h
400
990
330
660
Model
No. comp.
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For special requirements, a combination of both
dosing principles (batch and continuous dosing
principle) is also possible.
The new PRO-BATCH series combines many positive features and the experience of the recent decades. In the developing process, we especially
paid attention to the compact construction, easy
handling and operation, high precision and simple
cleaning of the batch.
The new design of the slide valves, the effective
helix mixer and transparent construction are meant
to assist the user.
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PRO-BATCH 4-180
PB-4-180 on a Co-Ex-line
Advantages:
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More precise batch mixer
Compact construction
Usable in various situations
Highly accessible
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GRANULE CONVEYING
PRO-VAC
Every extrusion process starts with the feeding of
the materials to the system. The right layout of
the system is a warrant for a high availability, low
dust contamination and energy efficiency with
great flexibility.
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In order to choose the right concept, talk to our
experts right from the beginning phase of your
planning.
We have the appropriate technical
solution and the right vacuum
system for both conveying of
small amounts of a single
material over a short distance
or tons per hour through a
huge production hall.
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Conveying system with PCH 400
Layout of a conveying system
Material-Minimising Control (MMC)
Vacuum pump with PCP pre-filter
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vacuum pump
with central filter
PCP
conveyor
storage hopper
The standard decentralized
principle of material conveying (see picture 3) is simple:
Each component is equipped
with a PCH material conveyor. When the conveyor
requests a material, the system
will connect the vacuum from the
pump. The conveyor will start to transport the
granule from the day bin or silo into the storage
hopper. Once the storage hopper is full, the material is drained into the extruder's weighing hopper.
In the central conveying principle, the main difference is that more conveyors will simultaneously
transport material. A more powerful pump will be
needed in the process, but in most cases smaller
conveyors can be used.
material pipe
weight
day bin
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Advantages:
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Layout for low abrasive wear
High flexibility
Centralized control
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CENTRAL VACUUM
PRO-VAC
More and more extrusion companies are changing to a centralized vacuum supply (moving away
from the system related vacuum production),
needed for the feeding of the raw materials from
silos to the machines.
Advantages like energy efficiency, noise reduction at the work station and a significant higher
output at lower cost are only a few reasons. The
uptime is increased while the maintenance effort
is decreased.
line 1
line 2
line 3
pump room
pump 1
line 4
pump 2
pump 3
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3x
filter
line 5
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Pump room
Central vacuum
Material conveyors
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Material Minimizing Control (MMC) has been developed to reduce the amount of scrap and waste
due to changeover of products and recipes. The
program makes sure that the material storage
hoppers of the dosing units are empty when the
changeover is initiated and that only a small amount of material is left in the weighing hoppers.
For the central vacuum, more powerful vacuum
pumps and pre-filters will be installed in a closed
room. The whole production plant will be supplied with vacuum through this central air line.
The conveyors can access the vacuum stream
and supply themselves as needed.
In addition to the optional hardware solutions for
vacuum supply, PLAST-CONTROL also offers many
software solutions for this specific application.
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Advantages:
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Noticeable lower energy consumption
High flexibility
Centralized control
No dust contamination in the production hall
Less noise in the production hall
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SOLVE PROBLEMS WITH
PIPE IDENT & PCH-E
Coupling identification with PIPE-IDENT
PIPE IDENT was developed to eliminate the incorrect connection of material feed hoses.
PIPE IDENT uses a wireless sensor (RFID) on the
removable flex hose which does not need a power
source. The fixed pipe side is connected to the
control system. The flex hose and the fixed pipe
side are paired via the system software. If the hose
is connected to the wrong pipe, then a visual indication is displayed on the coupling as well as on
the operator display. In this case the start-up of
the loading system is not allowed.
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maschine
in production,
dedusting active
switched to silo
PCH-E
switched back
on
12 min.
reaction time
reel change
count
[1ms]
level
good production
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–
–
–
–
>
200
350
600
1000
1000
µm
µm
µm
µm
µm
12 min.
reaction time
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PIPE-IDENT
Dust and contamination filtration with PCH-E
PCH-E conveyor
Dust and contamination filtration with PCH-E
Dust and contamination of the virgin material often creates problems in the extrusion process.
Long transport distances and many elbows between the silos and the machines produce angel
dust and angel hair. These contaminates should
be removed before entering the extruder by using
filtration devices.
For this type of problems, there are many solutions available. Just ask our engineers.
Advantages:
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High transparency
Energy efficiency
Customized design
High reliability
Efficient filtering of dust and angel hair
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REAL TIME PLANT-WIDE
MONITORING WITH
PCC
The PLAST-CONTROL Central PCC ensures plantwide connection of your extrusion lines. The PCC
is a powerful and convenient tool for accessing
and storing all production data – in real time.
All production data is displayed centrally and optionally on Personal Computers integrated into
your plant-wide network.
Precise material balance sheets, quality control,
central data saving and production supervising
are possible without the need of large Information Technology budgets. The basic software package includes a number of sophisticated data logging and order database applications. Custom
screens can be implemented for a specific customer request.
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Optionally, production specific data from your
system network can be sent to the PCC.
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Advantages:
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PCC-Screen
OEE-Diagram
PCC-Scheme
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OEE (Overall Equipment Efficiency)
Manufacturing transparency in real time
Material balance sheet
Central data storage and retrieval
Online access to all production parameters
Material database capability
Scrap accountability
Central logging of machine status and alarms
PLAST-CONTROL remote support via modem
Connection to plant network
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PROFILE MEASUREMENT
PRO-FIL
Non-contact AirCC sensor
PLAST-CONTROL’s experience in building and
designing measurement sensors for the on-line
gauge measurement of films has given rise to several new technologies. The patented sensor AirCC
was developed especially for sticky and surface
sensitive films.
The AirCC has two parallel working sensors which
create different capacitive fields. This combination allows calculation of film thickness regardless of gap to film. Even a constantly changing air
gap (from 100 to 350 µm) doesn't influence the
result.
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Profile display
Measuring heads
Profile measuring with round scanner
C-SCAN
New C-SCAN solutions for barrier and cast film
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Capacitive Measurement sensor
Capacitive measurement sensors from PLASTCONTROL in combination with direct driven scanner rings in low-weight aluminum design are the
guarantee for low maintenance profile measurement without any slip (precise allocation).
An effective capacitive alternative to radioactive
sources is available with the new C-SCAN, mounted
after the collapsing frame on blown film lines or
after the chill rolls on cast lines and measures
across the web.
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Advantages:
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The right measurement solution for all applications
Measurement of sticky (i.e.EVA) and soft film
without damage with AirCC
Integrated film temperature measurement
Barrier film measurement with C-SCAN
Non-contact measurement of overall thickness
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PROFILE CONTROL
PRO-CON
PLAST-CONTROL, as one of the pioneers in the
development of automatic systems for the reduction of transverse direction (TD) profile tolerances has continuously developed and refined its
systems.
Functionally, the computer opening or closing of
actuators within the PRO-CON air ring will increase or decrease the volume of air in each segment. This influences the melt temperature and
in turn the film thickness during film blowing step.
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The existing thin areas in the film are directly
cooled when the melt comes out of the die and
therefore can no longer expand as much. The
film will remain thicker in this area.
PRO-CON has the same good response when it
comes to thick areas in the film. Depending on
the material and product, PRO-CON will correct
thick spots by decreasing the cooling air in this
area. Depending on the raw material and the product specifications, the film profile tolerances are
reduced to a possible minimum.
The air rings are available in 6 sizes.
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System ACS
PRO-FIL
sensor
TYPE
Model
Die l mm/inches
PRO-CON
PRO-CON
PRO-CON
PRO-CON
PRO-CON
PRO-CON
C-200/32
C-400/48
C-750/64
K-1100/80
K-1650/106
K-2200/128
80-200
200-400
400-750
750-1100
1100-1650
1650-2200
3-8
8-16
16-30
30-44
44-65
65-86
Advantages:
profile measurement
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PRO-CON
air ring
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PRO-CON display
PRO-CON C-400 air ring
PRO-CON
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profile control
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50 % reduction of the base tolerances
No additional energy input
Output increase with MAGIC FLOW
Simultaneous control of thin and thick film areas
Easy retrofit
Retrofits of rotating/oscillating dies possible
Fast return on investment
Auto profile shift compensation
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BETTER COOLING WITH
MAGIC-FLOW
& PRO-CON DUO II
MAGIC-FLOW is the result of extensive research
in the increase of cooling capacity for blown film
lines.
This has been achieved by improving the aerodynamic flow path between the blower, manifold and cooling ring. Additionally, extensive
developments in the internal geometries of the
cooling ring and the complete redesigned lip
shape allows higher air speeds and air volumes at
the cooling interface. The net effect is that bubble stability is increased, transverse tolerances improved and higher machine outputs are achieved.
MAGIC-FLOW really does surpass all expectations:
output increases of up to 40 % are possible compared to standard double lip air rings.
An additional output increase becomes possible
by using PLAST-CONTROL’s double air ring technology, PRO-CON DUO II. Mechanical properties
will also be improved by using the DUO II. The
electrical controlled upper air ring elevator allows
for easy adjustment and accessibility.
DOWNGAUGING
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with PLAST-CONTROL
-6%
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The combination of “improved output – better
mechanical properties” ensures a fast return on
investment.
PRO-CON DUO II
Downgauging
IBC stack
Section view through the PRO-CON C-400
You can find more information about this product
in our PRO-CON flyer.
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Advantages:
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High bubble stability – fast return of investment
Perfect basic tolerances
Significant higher output, up to 40 % more
than comparable cooling systems
Better mechanical film properties possible
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PROFILE CONTROL
PRO-JET
The PRO-JET profile control is achieved through
the mounting of a segmented plate, underneath
an existing air ring. Adjustable air valves located
below the air ring, control the volume of airflow
in each segment.
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profile measurement
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profile control
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PRO-JET layout
PRO-JET installation
PRO-JET cut-out picture
The PRO-JET is suitable for stationary and moving
dies and have diameters from 100 mm -2500 mm
(4”-100”).
The basic tolerances are improved with up to 50%.
PRO-JET does not affect output rates.
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Advantages:
y
y
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Economic solution for retrofits
Immediate response
Low additional energy input
Auto profile shift compensation
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STATE OF THE ART
LINE CONTROL WITH
NAVIGATOR
The NAVIGATOR operator allows a simple graphical touch screen control of your entire extrusion
process, including extruder drives, temperatures,
blower controls, calibration cage, collapsing frame,
haul-off and treater. The NAVIGATOR can be easily adapted to new lines, upgraded or retrofitted,
irrespective of the Original Equipment Manufacturer.
PLAST-CONTROL produces many electronic components and the software package in-house, which
sets us apart from on-going technology obsolescence in the ever evolving computer world.
This enables us to provide our customers complete
service and spare parts for all our products for
many years along with a migration to the future
product.
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Also included is a comprehensive technical and
legal counseling during the installation and the
security check in the working environment of the
installed system.
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This flexible solution for existing extrusion lines
as well as for new lines enables you to implement
an identical operation philosophy throughout your
entire company. NAVIGATOR is available in many
languages.
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The configuration, implementation and documentation of all work steps are part of our service.
Advantages:
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NAVIGATOR-screen
Power distribution and drive control
Cabinets for CoEx-line
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Modular
Safety function
Retrofit/exchange of the old components
Long term availability of spare parts
Operation through Touch Screen
Implementation of clients’ individual wishes
Safety assurance of E-Stop circuitry
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IBC BUBBLE CONTROL
PRO-SONIC
PRO-SONIC can be integrated into all PLASTCONTROL systems or can be supplied as a standalone system. For accurate control of the bubble
diameter, speed is everything. PRO-SONIC incorporates non-contact high quality ultra-sonic sensors processed by ultra-fast signal processing hardware and software. Bubble diameter calculated
within 100 ms per update.
Upgrading to PRO-SONIC offers full non-contact
high resolution sensors and ultra-fast acting STV
control valve, reducing edge trim width (decreased scrap) and reduction in order change time.
Stepper motor driven air Throttle Valve (STV)
supplies instantaneous response to the control
required by the system. Layflat width variations
are reduced to a minimum. Startup requires minimal operator interaction.
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Ultra-sonic sensors
We have achieved width tolerances of less than
+/-2 mm (0,08 inches) on existing lines using the
latest generation of ultra-sonic sensors combined
with the newly developed air control valve.
Advantages:
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y
y
Fully integrated
Cost effective solution
Contact-free measurement
You can find more information about this product
in our PRO-SONIC flyer.
sensor 1
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0-10 VDC
(4-20 mA)
sensor 2
sensor 3
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frequency
converter
air valve
control
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Ultra-sonic sensors 1-3
IBC System control
Frequency converter
Signal converter
Blower IBC in/out
STV air valve
(Stepper Throttle Valve)
Ultra-sonic sensor
on calibration basket
calibration basket
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sensors on frostline level
STV
air valve
G
IBC in
H
M
IBC out
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BUBBLE CONTROL
PRO-WIDE & PRO-CAGE
Width Control PRO-WIDE
A width measurement bar is installed between the
collapsing frame and the winder. The measuring
sleds precisely detects the edges of the film by
means of infrared sensors. For film with gussets,
the width measurement can optionally be made
with ultra-sonic sensors on the calibration cage.
Width adjustments are made by automatically
opening or closing the calibration cage on IBC
systems or with a digital air valve on non-IBC lines.
Calibration Cages PRO-CAGE
The calibration cage is possibly one of the most
overlooked items in regard to the influence it has
on film quality and profile tolerance.
The PRO-CAGE range of cages offers an innovative
design with a rigid construction and precise control of the cage position throughout the operational range. You can choose between two types
of cages: the M series with high precision double
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pivot self centering, easily exchangeable rollers
or the L series with single pivot operation.
Both devices feature a choice of roller surfaces for
different applications.
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Width measurement
Motor
Ultra-sonic sensor
PRO-CAGE Type L
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Advantages:
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Precise width control
Various roller surfaces
Rigid construction
Compact design with wide adjustment range
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GAUGE MEASUREMENT
PRO-LAB II
The PRO-LAB II has a touching sensor for the absolute, real thickness measurement of film profiles
according to the norms DIN 533370 / ISO 4593 /
ASTM-D 6988-08.
In addition to the touching sensor the system is
available with a capacitive sensor for a continuous measurement mode or with a combination
of both sensors.
To analyze the thickness distribution, a film strip
is put into the holding device of the PRO-LAB II
system. The measuring
value is taken with the
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mechanical detection
head at selectable
distances or continuous
with the capacitive sensor.
The maintenance free
stepper motor moves the
film strip step by step by
the mechanical detection
sensor.
The PRO-LAB II basic
system is equipped with
a serial interface, so that
the system can be connected to a customer PC.
The software package is
Windows based and has a
user friendly environment
allowing a professional
profile analysis. Based on
meaningful profile
graphics, average values,
min. and max. values,
the tolerance of the pre-selected set points
will be easily detected.
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PRO-LAB II (standard version)
PRO-LAB II the mechanical detection with film guiding
device and tablet PC (optional)
Tablet PC with PRO-LAB II software (optional)
You can find more information about this product
in our PRO-LAB flyer.
With the help of Windows, these measuring
results can be documented with
product or order numbers,
archived or recorded.
D
Advantages:
y
y
y
y
Measurement according
to the norms DIN/ISO/ASTM
Easy handling
Automatic mode
Easy calibration
19
04.10.2016 9:28 Uhr
Seite 1
PLAST-CONTROL GMBH WALTER-FREITAG-STR. 15 · 42899 REMSCHEID · GERMANY
TEL. +49 2191 9480 0 · FAX +49 2191 9480 49
PLAST-CONTROL LTD. UNIT 17, LEEWARD ROAD · ASHTON-PRESTON · LANCASHIRE PR2 2TE · GREAT BRITAIN
TEL. +44 1772 769963 · FAX +44 1772 736357
PLAST-CONTROL INC. 65 PARKER STREET, UNIT 10 · NEWBURYPORT, MA 01950 · USA
TEL. +1 978 462 0306 · FAX +1 978 462 1425
PLAST-CONTROL ASIA LTD. 7F, NO. 155, KEELUNG ROAD · SEC. 1, XINYI DISTRICT · TAIPEI CITY, 110 · TAIWAN
TEL +886 2 3765 1808 · FAX +886 2 2767 2538
PLAST-CONTROL CHINA CO. LTD. UNIT 53 · FLOOR 11 · NO. 6088 HUMIN ROAD · SHANGHAI
TEL +86 21 5413 3383 · FAX +86 21 5413 3323
PLAST-CONTROL INDIA PVT. LTD. REDBRICKS · HDIL KALEDONIA 1ST FLOOR · SAHAR ROAD ANDHERI EAST
MUMBAI 400 069 · MAHARASHTRA · INDIA · TEL +91 9594 033 303
WEB SITE: WWW.PLASTCONTROL.COM
SUBJECT TO CHANGE WITHOUT PRIOR NOTICE · PRINTED IN GERMANY · 10-2016
BRO38-GB16-RZ5K
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