ProGal – Our core

Automation competence for your electroplating plant

The quality of a software is measured by how exactly it meets your requirements, how robust it is in everyday use, how it adapts to future technologies and how user-friendly it is.

We rely on

Intelligent algorithms
 They optimize the production process in milliseconds for maximum productivity.

Standard modules Mature and field-proven modules not only ensure process and software quality, they also shorten commissioning times

Individual programming Specific requirements are implemented via individual programming. Our competent team of developers always keeps a balanced price-benefit ratio in mind.

Industry standards
This makes you strategically independent and secures your spare parts procurement.

In detail

The ProGal electroplating control system is an open and variable system in the spirit of Industry 4.0. We use our intelligent simulation software to configure the right control logic for you on the basis of a digital twin:

Time-distance diagram based

With clearly defined process sequences, the paths of the transport carriages can be permanently stored. Although this limits the flexibility of the plant, it ensures high productivity and plannability.

Dynamized time – distance diagrams

If special process times have to be met or different processes have to be mixed, the time-distance diagram can be optimized in real time. Process and tolerance times are thus guaranteed despite mixing of the program sequences.

Free – flexible optimization

It is easily possible to map the enormous variety of process parameters, which can vary for each goods carrier, using our free optimization. These allow the maximum possible throughput in compliance with all process specifications.

Stop & Go

If the plant is a link in a production chain and, for example, the throughput needs to be adjusted in one of the following plants, the Stop & Go function is the first choice. Here, the entire process is divided into several sections, the respective sections are calculated with each other and executed.

Hybrid solution

In certain cases, a combination of the different control logics turns out to be the best solution during the analysis. Thus, a change of the control model is possible without any problems even during production.

In this way, we can ergonomically map simple to highly complex plants by assembling the software from different modules exactly to your needs.

No more but no less. You can choose freely, change the control logic at a later time or add further modules.

The Facts

Use of Siemens – PLC (S7/TIA) for direct control of the field level

Control and monitoring of a wide range of peripheral devices, so that all relevant process parameters can be maintained

ERP connection for process optimization and smart information flow. This means that data does not have to be entered twice

Client – server – technology for a stable production, even if several operators work with the software simultaneously

Multi-user capability/ operator terminals/ tablets/ smartphones

Continuous further development of the software

The ProGal modules

Handheld

With this module, the ProGal process control can be operated via a remote control, a handheld, if desired. This not only increases the ease of operation of the plant, it also significantly reduces commissioning, maintenance and repair times.

Quality management

Article-specific “quality profiles” can be defined, on the basis of which the system carries out an automatic check and, if necessary, triggers, for example, a red locking printout at the relevant unloading position.

Process visualization

For each bath/bath group an animated visualization window is provided, in which the aggregates can be directly switched on, off or to automatic.

Maintenance

The maintenance module supports you in performing and documenting maintenance tasks. At any time, you have an up-to-date list of overdue, pending and future maintenance tasks. All maintenance operations are recorded with the date and name of the responsible employee.

Bath analysis module

The bath analysis module automatically calculates the bath additives on the basis of the analysis. With an interface to ProGal, bath analyses depending on the throughput of goods can be carried out without any problems.

Rack manager

The rack manager uses RFID technology to manage the rack park, automatically controls preventive rack maintenance and documents the maintenance work performed.

History

This module records and documents the changed settings for article master data, process sequences and other parameter settings that are made on the ProGal process control system. This means that each change is recorded with the date, operator and reason for the modification.

Logging

All process data (date, time, duration, sequence program, batch number, setpoint/actual values of the rectifiers or the temperatures, any alarms that may have occurred) are archived for each batch and can be printed out if required (DIN EN ISO 9000ff).

Energy management

With the energy management system, the energy consumption of individual plant components such as rectifier heaters and pumps can be managed, logged and analyzed.

Multi-user capability

All current information about the production or the plant can be conveniently queried via additional workstation versions. In addition, all product master data, process sequences and control parameters are maintained here. In principle, there are no restrictions with regard to the range of functions at other workstations compared to the master computer.

Freely editable sequence programs

Countless different sequence programs can be defined, whereby the number is limited solely by the hard disk capacity. For each sequence program, the bath parameters such as the bath sequence, exposure, tolerance and drip times, etc. can be entered.

Database views

With the installation of the database interface, the ProGal master/process data can be queried or analyzed e.g. with MS-Excel in actual time. For this purpose, an example Excel macro is included in the delivery, which is available for free use (per plant).

WEBApps

Various reports and information (logs), but also plant operation (digital inputs/ outputs/ temperature controllers/ rectifiers/ dosing stations) are made available as a web service and can thus be executed on mobile devices.

Good/bad classification, rework detection

This module can be used to record and report on the rework (total goods carrier or per piece). For this purpose, the order item that was also loaded on the goods carrier as rework (partial or full loading) is marked as rework when it is released.

Alternatively, rework can also be identified via a special rework sequence program. Optionally, the order items can be evaluated at the unloading point via the classification “good/reject/rework” incl. defect pattern feature and are available for a corresponding report.

Memory optimization module

This modules enables the goods carriers to be transferred from the raw materials store to the plant in a throughput-optimized manner. Furthermore, the storage is managed in such a way that the empty, unprocessed and finished goods carriers are sorted according to the requirements.

“Virtual” memory management module

In order to achieve optimum throughput even for plants with no or few storage locations, the goods carriers loaded on manual loading carts outside the plant can be registered with the control system. The control system requests the next goods carrier from this raw material buffer to the loading point in a throughput-optimized manner. The operator has approx. 60 seconds to move the corresponding trolley to the loading point. To achieve optimal and safe software (input) and ergonomics, it makes sense that the loading trolley or the goods carrier is coded (binary or RFID…).

Photo image module

This module can be used to take a photo of the started as well as the finished goods carrier and archive it in the batch report. This makes it possible to subsequently check and examine, for example, the loading of the goods carrier before and after coating.

High availability system (ProGuard)

The redundant master computer system consisting of 2 computers is constantly synchronized via the ProGal high availability software module. For this purpose, in addition to the data backup, which is still carried out once a day on the replacement system, all current occupancy data is also exchanged, so that in the event of a failure of the master computer, the replacement master computer can immediately take over production after acknowledgement, without any hardware or software changes having to be made. In a worst-case scenario, the data stored in the database (article/recipe/production data) for the last 24 hours at most is lost during the switchover. After the switchover to the replacement system, DiTEC must be contacted to switch the system back to the original system. This module can be used to compensate for a master computer failure in approx. 90-95% of cases.

Hybrid software module (free system<->ZWD)

This software module enables switching from ZWD-guided (e.g. monocharge operation) to the free system (flexible system) and back. When switching from the free system to the ZWD system, the plant must be moved to the initial position (initial position ZWD: A defined bath occupancy is the prerequisite for starting the plant, initial position start free system: As a rule, the baths must not be occupied with goods carriers) These parameters are clarified together in advance.

Coating thickness calculation

With this module the average coating thickness of a batch can be calculated.

Cockpit

This tool is used to inform the operator-level about current KPIs. With the help of the cockpit displays on large screens, a high level of production transparency is achieved. When entering the production hall, the “situation” can be captured at a glance.

Dashboard

The detailed KPI overview is primarily used in control centers and master offices. A quick overview of the self-selected, most important key figures supports the responsible personell to initiate necessary measures in time.

Test/check lists

There are recurring tasks that have to be performed according to a certain pattern. Automatic checklists ensure complete documentation and make sure that nothing is forgotten. When a measured value is entered, for example, branched checklists forward the user to the correct follow-up test or measure.