Brückner One
The comprehensive solution from Brückner Maschinenbau and Brückner Servtec
Integrated Machine Control
The Heart of the system and the operating software of the machine provides all the features you need for a successful production.
- Complete system control: Intuitive operation enables control over all aspects of the system from the outset.
- Fast production start-up: Seamless commissioning until full production output is reached.
- In-depth troubleshooting: Comprehensive diagnostics in the event of faults, including circuit diagram display and customizable trends for fast solutions.
- Flexible production recipe management: Simple change of production settings by loading recipes, without manual intervention.
Cockpit
The cockpit displays the production status and quality level of the last roll. It saves the history of the last 12 hours and simultaneously manages the service tasks and the next product list. It offers a live KPI view. New applications can be started via this cockpit thanks to direct quick links.
Your benefits:
- Most relevant information in one page
- Enhancement of better collaboration
Advanced Viscosity Display
The Advanced Viscosity Display shorten reaction time on film property changes and offers the advantage to compare different lines. Process changes will be visible sooner and offers a longer lifetime of the TFE Lock rollers due to optimized working point.
Your benefits:
- Optimized Quality control
- Reduction of laboratory time
- Less maintenance costs
- Easier line handling
Operating Point Assistant
The Operating Point Assistant is a software module that supports the intuitive and safe change of speed, thickness and output of a stretching line.
By changing one parameter and automatically adjusted machine settings the software offers:
- Fail save operation
- Less complexity of production
- Faster product change
Thickness Controll Engine (TCE) - Basic Functions
- Measure and Control your thickness profile.
- All measured thickness profiles are stored in a database.
- These historical profiles can be viewed at any time for analysis purposes and can also be compared with other points in time.
DieBolt Tool
- With the DieBoltTool the system will find the time of the best profile in the past 8 hours production.
- It shows then the current profile and the historical profile to compare the thicknesses.
- Also the difference of die bolt temperatures is displayed.
- It is possible to set the old target temperatures and thus very quickly restore the previous good production.
Thickness Map
- The saved historical profiles can be displayed graphically as a color map. The thickness is color coded.
- The thickness distribution of individual rolls can be recorded at a glance, and longer periods of time can also be displayed.
- The user can do easily long-term process analysis. It is also possible to display MD trends and TD profiles within the map.
Recipe Manager
The feature saves and manages existing recipes. It can generate recipes from historic mill rolls or current production parameters, offers easy customisation options and then sends the corresponding recipe to the production line with a single click.
It also offers a comparison function for different recipes.
Your benefits:
- Systematic analysis and setup
- Improved uptime and process
Product Manager
The product manager facilitates the definition and management of end products. The user can either define products or there is a list of predefined products that are added automatically.
The product is in focus and brings together materials, recipes and machine data.
As customer values in the software, this tool provides product-related KPIs and statistics and gives the machine data a business meaning.
Raw Material Manager
The raw material manager facilitates the definition and management of the materials. It integrates with the rest of the applications:
- The materials are used in other apps
- Managing materials is reflected in the apps that are using materials
This toll allows the user to track the material from the silo to the layer of the film that was produced.
Film Production Historian (FPH) - Basic Functions
This function offers the advantage of visualising the historical production data of a line.
Your benefits:
- Explore production information since the line was started
- View the most relevant data for campaigns, rolls and more
- Display detailed information on relevant KPIs and material consumption
Energy Monitor
The energy monitor tracks and analyzes energy consumption of the film production process. Energy consumption is shown specifically,
i.e. per kg of film produced, and divided into electrical and thermal energy consumption.
Your benefits:
- Helps identifying saving potentials
- Accurate feedback of taken measures
- Energy cost calculation per product
- Increased awareness on energy
Advanced Film Production Historian (FPH) Tool
The Advanced Film Production Historian (FPH) tool displays aggregated data for any time period. It offers the possibility to select random time periods, yield and uptime KPIs with details are available and it shows production statistics.
Efficiency information is also available for campaigns, including revenue and uptime KPIs with details and capacity KPIs. For each campaign, the tool offers the possibility to compare KPIs set for that specific campaign.
Comparison Tool
The comparison tool is used for
- Solving issues in production
- Optimizing the production
- Finding reasons for line behavior
by comparing a “successful” with a “less successful” production.
It only works with FPH and recipe manager.
Uptime Tool
The Uptime Optimizer tracks and diagnoses as a tool the downtimes of a production line.
Your benefits:
- Minimizing the downtimes of a line
- Specifying the real reasons of downtimes
- Aggregating the data and showing comprehensive statistics for specific periods
Reporting Tool
The reporting tool allows users to define reports in a customizable format. Multiple reports can be defined on various production informationen.
Your benefits:
- Define custom reports specific for your needs
- Run the report on any period
- Define multiple reports for multiple needs
Laboratory Tool
Laboratory Measurement Collector gathers and visualizes the laboratory measured parameters for a mill roll. It assigns the mill roll quality based on the measurements and configures its parameters based on the measuring devices available in the laboratory.
Gear Box Analysis
This is a standard tool for the main extruder. By means of permanent (24/7) monitoring of vibrations, the feature enables early detection of problems or incipient component failures such as misalignment of motor and gearbox, motor or gearbox bearing failure or increased wear on gearboxes. A reporting tool also helps to identify parts that need to be checked.
Your benefits:
- Reduce efforts and costs as less inspections are needed
- Avoid risk of unplanned machine downtime and production loss
- Less efforts and more convenience
Roller Bearing Analysis
Vibration sensors detect the vibration level on the bearings of certain stretch and pinch rollers (MDO) or corona and pinch rollers (Pull Roll).
An early warning system uses real-time data analysis to indicate the condition of the bearings and the roll surface. In the requested expert‘s report the root cause of the vibrations is identified.
Your benefits:
- Reduction of effort and costs through better planning of maintenance activities
- Avoid risk of unplanned machine downtime and production loss
- Less efforts and more convenience
Roller Roundness Analysis on Nip Rollers
The geometry of the nip rollers and corona rollers can be analysed in many ways to identify wear on the rubber surface or critical line speeds.
Production downtimes can be limited as root cause analyses of vibrations are easily accessible and in some cases even failure predictions are possible. Longer roller downtimes are avoided or less poor film quality is produced.
Your benefits:
- Limitied production downtimes as root cause analyses of vibrations are easily accessible and in some cases even failure predictions are possible
- Avoid longer roller downtimes are avoided
- Less poor film quality in production
Roller Chain Condition Monitoring
Roller Chain Diagnosis is used to assess the vibration condition of the chain rollers. Possible missing or loose chain rollers are recognised. An early warning system in the control unit also indicates the overall condition of the chain rollers.
Your benefits:
- Reduce maintenance efforts and costs
- Better plan of maintenance activities
- Avoid risk of machine downtime and production loss
- Less effort, more convenience
