which requires tight process control — a level of control that ’ s only achievable by using complex software and algorithms . Semiconductor plants use drive modules to facilitate wafer production , which APC can control the speed of . Adjusting the motor speed according to production demand can help reduce energy consumption and avoid premature wear and tear by ensuring the drive doesn ’ t run at excessive speeds for long periods .
Importantly , APC helps minimise process drive , shift , and variability and , in doing so , increases process capability and reduces product scrap . The same Government survey found that 99 per cent of large manufacturers monitor their energy usage , so investing in APC tools means they can act on the results and make a positive change .
In the case of TwinCAT , it supports modular extensions , meaning functional changes and additions can be made at any time . Therefore , the openness of the control system not only allows the integration of third-party components , but also customised retrofits for existing machines and system — ensuring flexibility and investment protection .
Consistency and quality
In process manufacturing , consistency is vital for converting raw materials into robust , highquality products — whether it ’ s food and beverage , pharmaceuticals or cosmetics . Returning to semiconductor production , manufacturers must be able to align the mask with the utmost precision . This means repeatedly placing the mask over the same location as the chip goes through multiple rounds of lithography .
APC platforms like TwinCAT allow manufacturers to improve their control over a wide range of process parameters , helping them weed out inconsistencies and anomalies . For example , in the food and beverage industry , APC can control fermentation conditions , such as temperature , pH , and oxygen levels . It can also standardise packaging operations , such as filling , sealing and labelling to reduce waste — a key concern for the industry . Similarly , it optimises purification processes , such as chromatography
and filtration , to remove impurities and recover the desired product .
In all cases , real time data analytics provide manufacturers with actionable insights , so they can make informed decisions and quickly address any production issues by adjusting key parameters . Consequently , APC can improve product yield and quality , optimising production and keeping customers happy in the process .
APC technologies are the unsung hero of production efficiency and quality . Using real-time data analysis , predictive modelling , and other complex algorithms , APC can fine-tune operations to streamline performance . This can have significant pay-offs , including process stability , higher-quality products , and operational efficiency . Meanwhile , opting for open , PCbased control technology such as TwinCAT can further support manufacturers by protecting their APC investment .
For more information on TwinCAT and how APC can get the best out of your process , visit the Beckhoff website .
For further information , please visit www . beckhoff . co . uk
Issue 71 PECM 87