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Abstract(s)
Atualmente as empresas lutam pela procura de processos produtivos mais rápidos e eficientes sem colocar em causa a qualidade dos produtos fabricados. A entidade acolhedora do presente projeto é um fabricante de renome, desde 1970, de reservatórios para aquecimento e acumulação de águas quentes sanitárias, sendo o seu foco principal o fabrico de bombas de calor em aço inoxidável. A construção dos reservatórios é efetuada sobretudo por meios manuais que envolvem processos de conformação e soldadura de chapa e de tubos, havendo um potencial de defeitos decorrentes maioritariamente da construção soldada. Com este pressuposto, durante o processo produtivo, os produtos são sujeitos a uma série de testes qualitativos de forma a verificar a conformidade das construções para posterior colocação no mercado. De entre os processos de fabrico praticados na empresa para a produção dos equipamentos referenciados, a soldadura identifica-se como o processo crítico. Os reservatórios são produzidos numa primeira fase, no setor um e consumidos posteriormente no setor dois. Deste modo, necessitam de ser verificados quanto à sua estanquicidade. Para este efeito, os depósitos são submetidos a um ensaio não destrutivo onde são cheios com água e pressurizados de forma a inspecionar visualmente defeitos de fabrico decorrentes da construção soldada. Este posto de ensaio acaba por ser o gargalo do fluxo produtivo da entidade acolhedora pois é realizado de forma manual e controlada totalmente pelos colaboradores. O conceito de Indústria 4.0, conhecido também pela quarta revolução industrial, vem mudar mentalidades acerca dos processos produtivos e a automatização de postos de trabalho. Esta revolução permite, por meio de autómatos e dispositivos de entrada e saída, automatizar postos de trabalho, com o objetivo do aumento da produção e acima de tudo da qualidade do fabrico. Este projeto visa automatizar o posto de ensaio de estanquicidade, utilizando Controladores Lógicos Programáveis (PLC) e Interfaces Homem-Máquina (HMI), de forma a diminuir o impacto do gargalo produtivo existente na produção atual da empresa acolhedora.
Nowadays, companies strive to find faster and more efficient production processes without jeopardising the quality of the products manufactured. The entity hosting this project is a renowned manufacturer, since 1970, of tanks for heating and domestic hot water storage, being its main focus, currently, the manufacture of stainless-steel heat pumps. The construction of the tanks is mainly carried out by manual means involving sheet metal and pipe forming and welding processes and there is a potential for defects arising mainly from the welded construction. With this assumption, during the production process, the products are subjected to a series of qualitative tests to verify the conformity of the constructions for subsequent placement on the market. Among the manufacturing processes practised in the company to produce the referred equipment, welding is identified as the critical process. The tanks are produced in a first phase and consumed later, in a subsequent phase within the same manufacture. Therefore, they need to be checked for leak tightness. For this purpose, the tanks are subjected to a non-destructive test where they are filled with water and pressurised to visually inspect manufacturing defects arising from the welded construction. This testing station ends up being the bottleneck of the production flow of the host entity as it is carried out manually and controlled entirely by employees. The concept of Industry 4.0, also known as the fourth industrial revolution, has changed mentalities regarding production processes and the automation of work posts. This revolution allows, by means of automata and input and output devices, to automate workstations, with the aim of increasing production and above all manufacturing quality. This project aims to automate the tightness test station, using Programmable Logic Controllers (PLC) and Human-Machine Interfaces (HMI), to reduce the impact of the existing productive bottleneck in the current production of the hosting company.
Nowadays, companies strive to find faster and more efficient production processes without jeopardising the quality of the products manufactured. The entity hosting this project is a renowned manufacturer, since 1970, of tanks for heating and domestic hot water storage, being its main focus, currently, the manufacture of stainless-steel heat pumps. The construction of the tanks is mainly carried out by manual means involving sheet metal and pipe forming and welding processes and there is a potential for defects arising mainly from the welded construction. With this assumption, during the production process, the products are subjected to a series of qualitative tests to verify the conformity of the constructions for subsequent placement on the market. Among the manufacturing processes practised in the company to produce the referred equipment, welding is identified as the critical process. The tanks are produced in a first phase and consumed later, in a subsequent phase within the same manufacture. Therefore, they need to be checked for leak tightness. For this purpose, the tanks are subjected to a non-destructive test where they are filled with water and pressurised to visually inspect manufacturing defects arising from the welded construction. This testing station ends up being the bottleneck of the production flow of the host entity as it is carried out manually and controlled entirely by employees. The concept of Industry 4.0, also known as the fourth industrial revolution, has changed mentalities regarding production processes and the automation of work posts. This revolution allows, by means of automata and input and output devices, to automate workstations, with the aim of increasing production and above all manufacturing quality. This project aims to automate the tightness test station, using Programmable Logic Controllers (PLC) and Human-Machine Interfaces (HMI), to reduce the impact of the existing productive bottleneck in the current production of the hosting company.
Description
Keywords
Reservatórios Água Quente Sanitária Soldadura Ensaio de Estanquicidade Indústria 4.0 Autómatos PLC HMI Tanks Sanitary Hot Water Welding Leak Testing Industry 4.0 Automation