The well-known concrete block producer on the Kuwaiti market, MS Bonyan is operating several concrete block plants. Thereof a SP 2000 plant delivered through Schlosser Company of Germany and a fully automatic operated Schlosser SV 30 block plant, refurbished, delivered and commissioned through Contec. The SP 2000 plant originally was installed as an economical block plant designed for midsized block factories and supplied in 2002 to Bonyan.
In order to adjust to the increased requirements of the market it was decided to upgrade the SP 2000 plant to be more versatile.
Vibration system and mold clamping
The SP 2000 was standard equipped by two vibrating tables, each equipped by a countercurrent vibrator 25 KN force. This was sufficient to manufacturer standard pavers, interlocks and blocks. However, through rising market demands the company was aiming to manufacture more heavy concrete products like some curbstones, which required a stronger vibrating force to assure a perfect compaction. In addition, one was aiming to reduce and optimize cycle times for the standard interlocks and blocks production. Therefore, the costumer wanted to install a similar vibrating system to the already known vibrating system of their Schlosser SV 30 block machine SynchroVario plus (SVplus). The challenge was to integrate such a strong and flexible vibrating system of max. 140 KN into the overall not that strong designed block machine SP 2000.
Pallet advance and proportional valve
The pallet advance of the SP 2000 is standard equipped by a so-called FMH valve, which controls via a mechanical curve the accelerating and the decelerating speed of the pallet advance. As long as just a few standard products, such as standard interlocks or blocks are produced this mechanical controlled pallet advance device represents an economical and functional solution. Since the costumer was aiming to manufacture more sensible products, in respect of conveying as well, like 50 mm thick curbstones and various other conveying sensible products on the SP 2000 block machine, the stiff pallet advance control through the FMH valve was not suitable anymore.
Contec equipped the hydraulics of the SP 2000 block machine by a proportional valve with an integrated onboard electronic, which is controlled via Profibus and an electronic control card. In order to determine the different speed positions, a touch less digital sensor was installed. By the 3 components, proportional valve with an integrated onboard electronic, an electronic control card with Profibus as well as a touch less digital sensor, all different required ramps and its diverse speed switching positions as well as its various accelerating and the decelerating speeds can be adjusted conveniently from the control panel now.
Draw sheet device and control
Contec integrated into the existing Siemens Simatic S5 PLC of the SP 2000 block machine a new operating panel and a remote control via ´Team Viewer´, allowing remote online control, if required. The PLC control was modified to control the new vibrating system; the new pneumatically mold clamping device, the new proportional valve with an integrated onboard electronic and digital positioning sensor as well as the new draw sheet device. This top to bottom upgrading was completed and handed over to the customer by Contec in August 2018.