Imagine a CV line automatically gearing itself for production of high-voltage and extra high-voltage cables only by selecting the desired product. Our futuristic project is on the near horizon.
Imagine a future where your production line only needs to be told your desired product, and it will autonomously select all the parameters and instruct the necessary phases of production. That is the future we are aiming for. Increasing the level of intelligent automation and more sophisticated expert system guidance are the paths to more autonomous production lines. For a traditional CV line, we have developed several individual features towards this greater goal.
Simulations versus curing reality
Digital twins have been a trending topic for a while in industrial applications. Our solution in this direction is the Online Curing Control. It’s not just a digital twin of one machine trying to compare predicted behavior to real values but a digital model of the crosslinking process itself. Based on decades of development put into NCC curing calculation, this is a continuity of the same software. Comparing a handful of the most meaningful process values to the simulated recipe gives us a realtime look into the process’s current state. This allows for immediate adjustments, ensuring optimal curing conditions and reducing the risk of defects.
Intelligent control systems
Two of the most influential parameters affecting the crosslinking process are conductor temperature values after both induction heaters. We have recently developed a system for automating induction heater calibration and power control, reducing manual efforts by one further step. The Intelligent Induction Heating system automatically calibrates and controls the induction heaters to always give you the exact temperature increase you desire, without the need for manual calibration for each conductor. The system is also capable of adjusting the feed power during changes in conductor compactness or quality to maintain the needed temperature increase. This is the first and only (patent-pending) system capable of measuring the conductor temperature increase inside the CV tube. This innovation not only enhances precision but also significantly reduces downtime and human error.
Quality monitoring and assurance
Utilizing precise laser measuring and state-of-the-art machine learning methods, we offer continuous quality assurance and improvement through the Topography Scanner. Creating a 3D surface map enables us to distinguish surface defects reliably, which are then organized into predefined classes based on severity and type. Having the device on your CV line eliminates the need for manual surface inspection, with the added benefit of process improvement opportunities. Precise submillimeter- level measuring of the cable shape and lengthwise surface smoothness tells us a detailed story about the entire production history through extrusion and curing processes. This leads to enhanced product quality and consistency, reducing waste and rework.
Process improvement tools
One of our recent innovations for VCV line productivity and quality improvement, known as MRC, makes it possible to control the cable geometry even when reaching unprecedented production speeds of HV and EHV cables. Process parameters for MRC are calculated with the above mentioned NCC software, which can be further optimized by having a Topography Scanner on the same production line. Creating an optimization loop between the two, where one device controls the geometry and the other measures it precisely, will ensure that the optimum parameters overall are swiftly found. This synergy not only boosts efficiency but also ensures that the highest quality standards are met consistently.
Process performance-based maintenance
Implementing the solutions above provides more sophisticated tools for applying performance-based process maintenance on the CV line. The benefits are obvious: negating unnecessary production stops and unplanned delays due to maintenance. By continuously monitoring and adjusting process parameters, we can predict and prevent potential issues before they cause downtime, ensuring a smoother and more reliable production process. The future of autonomy shines brightly Our next project is to create an umbrella solution integrating all these individual systems into a full process control system. Imagine having the world’s most experienced process engineer tirelessly perfecting your production. That’s closer to reality than ever before. With our autonomous CV line solutions under development. We are paving the way for a future where production lines are smarter, more efficient, and more reliable than ever.
Janne Harjuhahto