AUTOMATION AND MACHINE INSTRUMENTATION

Our constant development and updating of new technology and usable products, allow the achievement of the requested performance through the realization of a top-rated design, which leads to results measurable in terms of parts/length/cadence and with low environmental impact.

Our Technical Department for the Automation Design develops a workforce of over 30.000 hours per year, consisting of a team formed of 15 technicians who assume the role of project managers.

Project managers determine and implement the exact needs of the client from the very first beginning in the conception phase, with a feasibility study, and then in the executive phase, co-operating with the commission manager in the production activity.

The realization and development of the project are carried out in compliance with the planning in accordance to the client's needs and in harmony with the other figures involved in the realization of the project (building, mechanical, logistics’ figures, authorities,...).

The documentation that needs to be done is singularly defined for every project and the implementation schedule is to be set in the commission planning phase, considering also the time needed for timing and conformity test.

Examples of some documentation needed for a project:

• units definition, engine and sensor's list;
• performance level and risk analysis;
• technical file and CE labeling procedure;
• flow chart and PID;
• units layout;
• cable trays' routes and dimensioning;
• PLC units and BusNet nodes configuration;
• network switch and repeater dimensioning;
• circuit diagrams for automation control panels and plant design;
• details for the machine instrumentation system implementation, with definitions and design of the necessary brackets;
• terminal blocks and definition of splice cassettes;
• implementation of materials lists both for electric panels and machine instrumentation or systems;
• cable laying test and special cable usage test (dynamic laying, torsion, water cables,...);
• overheating assessment.

EUROGROUP has always paid attention to the environment and its protection, over the years together with its customers, it has developed important projects for a Green policy.

In particular we can mention systems:

• Fumes treatment from Fusion furnaces Aluminium, Glass, Solid Waste and paper processing;
• Construction of electrical panels and systems for the control of small Hydroelectric Power Plants in Italy and auxiliary systems dam in Honduras;
• Bio Gas Cogeneration plants and located in the national territory;
• Hydrogen Production plants connected directly to the user and capable of generating hydrogen according to consumption, allowing the removal of typical problems due to hydrogen storage in special areas, the transport and the maintenance of cylinders;
• Machines for the Recovery of Freon from appliances and air conditioners;
• Photovoltaics and wind sector.

All of the electrical panels related to the automation systems are realized in a very careful way directly in the main factory in Silea (Treviso), every panel being then rigorously tested and specifically examined.

As for the assembly and the electrical panels wiring, the working area is equipped with the most updated equipment in order to optimize the wiring phase and the handling of electrical panels.

A specific warehouse, dedicated to the rotation of the material used in the electrical panel room, allows a fluid management of the whole manufacturing process, starting from the materials supplying and its quality-check, as provided for in the proven procedure operated by EUROGROUP.

The next step consists in dividing the material into production batches and creating an apposite assembly kit, which allows an essential reduction of time for the technicians for the wiring phase in the searching of the needed material.

A specific section is reserved for the mechanical implementation of the electrical panels; the components are assembled into banks of cabinets with control panels drilled for the insertion of buttons, selectors and indicator lights.

We start working on the inside of the cabinets implementing the plastic structure for the cable layers, where the cables are then laid for the wiring of the power and auxiliary circuits; then follows the work on the cabinets' surface.

The inner board is then completed with the identification and positioning of the needed devices, as provided for in the electrical diagrams. Every unit is identified and labeled, the terminal blocks are placed and every terminal is numbered. It is now possible to proceed with the wiring of the electrical panel.

In the Power Centers (or MCC) are implemented the distribution systems realized with copper bars and insulators positioned in conformity with the designed project, in order to be short-circuit proof as required in the specifications.

When implementation and wiring phases are through, the electrical panels enter the testing area, where every panel is rigorously tested and specifically examined, in conformity with the harmonized standards:

CEI EN 61439-1 2012-02, class. CEI 17-113/1;
CEI EN 60204-1, class. CEI 44-5, with the national technical standards and specifications CEI 64-8, with the Bassa Tensione (Low-Tension) (LVD) 2014/35/UE and EMC 2014/30/UE directives.

Electrical panel tests include:

• insulation resistance measuring;
• dielectric strength test;
• continuity between the ground and the protection circuit;
• wiring implementation test;
• emergency circuit test;
• signal device test;
• power circuit test;
• control circuit test;
• PLC test, digital and analogical I/O board addressing and test;
• ignition test for every device.

Functional tests involve PLC parametrization and ignitions; every single PLC board's operation is tested, as well as the functioning of every digital and analog port. Every wiring and testing process is recorded on specific office sets of forms, in order to allow a perfect traceability within the whole manufacturing process of the electrical panel.

EUROGROUP's quality procedures involve periodic tests for all of the equipment used in the testing process. The same quality procedures are applied also for the test of all the equipment used in every manufacturing process, including individual equipment.

The implementation of the machine instrumentation systems can take place whether inEUROGROUP's workshops or in the customer's site.

Accurate design and planning allow to realize the requested machine instrumentationsystem in compliance with the timing needed by the client, and in harmony with the other figures involved in the realization of the project (building, mechanical, logistics’ figures, authorities,...).

The implementation of the machine instrumentation systems develops in different phases:

• laying of cable layers with metal channels and protective sheathing, placing and implementation of engines, sensors and other devices (solenoid valves, analog sensors, proportional valves, weighing, temperature sensors);
• correct and safe placing and installation of electrical panels, control panels, electronic terminal blocks or BUS distributor;
• placing and connection of engine power cables and auxiliary multi-cable and equipotential connections.

Once these phases are complete, tests take place, in order to check tension, protection circuitsand connections, followed by the final test of simulation of precessing (dry run testing), and then by the commissioning and the client final acceptance.

Each and every EUROGROUP technician, operating in the automation sector for the realization of machine automation systems, follow courses, provided by EUROGROUP, in order to be kept up to date for every technical matter and innovation, with particular attention to the safety issue in the working site.