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Online Testing Cell Systems

Product catalog summary

Introduction
MonTech Werkstoffprüfmaschinen GmbH specializes in manufacturing rubber testing instruments and laboratory solutions. Their products, engineered in Germany, are available globally and include rheometers, viscometers, and laboratory management systems, all adhering to high-quality standards.

Automated Testing System for Mixing Line Integration
MonTech's online testing cells integrate seamlessly into rubber mixing lines, providing fully automated quality control without operator involvement. These systems utilize robotic technology for sample handling and processing, are software-controlled, and interface with various host systems for efficient batch release and quality control.

Online Testing Integration
The testing cells come with standard devices for sample handling and preparation, with options for additional instruments. The system includes a sample infeed system, a 6-axis robot, and a cell controller with MonCell software, with optional units for tasks like sample separation and weighing.

System Overview
Online Testing Cells offer a compact, modular solution for batch release testing, featuring a rugged design and sealed environment to prevent contamination. They include a centralized workstation for control and communication, directly linked to production machinery for automated operation.

Automated Sample Processing and Traceability
The system ensures sample traceability through automated processes such as slab washing, conditioning, and cutting. It allows for manual sample infeed and features a drawer system for collecting lab test samples.

System Layout and Details
The testing cell structure includes access points for instrument compartments, a main control panel, and a safety-locking maintenance door. The control cabinet is air-conditioned and maintains positive pressure to keep the sample processing area clean.

Cell Interior and Component Layout
The interior is designed for safety and accessibility, with large maintenance doors for easy access. The modular design allows for quick subsystem changes, ensuring high uptime and system availability.

Cell System Architecture
The system uses a multi-layer software design with a Cell Master PLC for high-level tasks and a touch panel for feedback. Communication is based on industrial TCP/Ethernet for high data rates and consistency, allowing seamless integration with other systems.

Overview
The document provides a comprehensive overview of MonTech's Online Testing Cell Systems, designed to integrate with external host systems like MES, LIMS, and ERP. These systems offer optional testing cell control monitors for real-time monitoring and remote diagnostics.

System Architecture
The core component of each Testing Cell is a 6-Axis industrial robot, equipped with a multi-functional handling arm for tasks such as sample processing, labeling, and sorting. The system is designed for high productivity without requiring re-programming for different testing sequences.

Safety and Environment
Safety is prioritized, with the Testing Cell divided into functional areas with specific safety requirements. Safety measures include coded door handles, emergency shut-off buttons, and compliance with OSHA standards. The system is sealed and pressurized to protect against contaminants.

Sample Preparation Systems
The system ensures high reproducibility using volumetric sample preparation. Samples are conditioned and prepared for testing, with options for camera-based vision systems for alignment. The system supports FIFO priority for sample delivery and offers manual sample introduction for control checks.

Rheometers and Density Tester
The Testing Cell includes MDR and RPA rheometers, fully automated and integrated into the system. The RD 3000 density tester is also automated, providing accurate and repeatable density measurements, with features like automated lubrication and cleaning.

Maintenance and Accessibility
The design emphasizes reliability and ease of maintenance, with long-life consumables and industrial control technology. The system features quick swap designs for easy replacement of sub-systems and dedicated service screens for troubleshooting.

Sampling and Conveying Systems
Sampling systems are integrated into the mixing line, with options for cold and hot sampling. These systems ensure full batch and material traceability and can be customized to fit various environments.

Integration and Implementation
Testing Cells can be integrated into existing or new mixing lines, with considerations for sampling methodology and system placement. Integration projects are tailored to customer specifications, ensuring seamless connectivity with LIMS and ERP systems.

Utility Connections

Electrical supply: Typically 3-phase, 400-480V, 50/60Hz, 16 Amps with Ground and Neutral.
Compressed air: Minimum 6 Bar / 90 psi, 600l/min / 160gpm.
Water: Minimum 2 Bar / 30 psi, 50l/min / 13gpm.
Drain: Typically 1"; a re-circulating chiller system can be integrated if necessary.

Testing Cell Systems

Automated quality control testing enhances production by reducing operator variation and increasing precision.
Closed-loop control allows for dynamic adaptation during the mixing process.
Testing Cells reduce labor costs and batch release data time by 62% to 80%.
Data from up to three samples per batch is collected for production decisions.

Testing Methodology and Procedures

MonTech recommends sampling and testing frequencies based on various factors.
Example tests include cure testing, compression density, Payne effect, carbon black dispersion index, RPA viscosity, and processability.
Each test has specific cycle times and sample frequencies.

Online Testing Cell Configurations

Cells are equipped with instruments tailored to the mixing line's purpose and cycle time.
Configurations vary for carbon black and silica masterbatch and final mixes, as well as tandem and multi-purpose lines.

Return on Investment

Automated testing reduces labor costs and improves data quality.
Integration with management systems allows for optimization of compound and process parameters.
Maximum ROI is achieved when testing and processing work in unison.

Engineering and Customization

Testing Cells are customizable and can be integrated into any environment.
3D models ensure proper spacing and specification compliance before assembly.
Manufactured in-house at MonTech's facility in Buchen, Germany.

Catalog excerpts

Rubber Testing Solutions Online Testing Cell Systems

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MonTech´s Rubber and Polymer Testing Solutions at a glance MonTech Werkstoffprüfmaschinen GmbH is the world´s leading premium manufacturer of rubber testing instruments and laboratory solutions. Our extensive product range covers instruments for basic to high-end testing applications in quality control as well as research and development. This includes integrated laboratory software systems, technical and calibration services as well as world-class application support and consulting. MonTech testing solutions are engineered and manufactured entirely in Germany according to the highest quality...

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ONLINE TESTING CELL SYSTEMSThe lean industry 4.0 approach for completely automated quality control in rubber mixing plants The following brochure is a introduction in the world of fully automated online testing which has revolutionized batch release testing over the past years around the world. Besides significant cost savings and shortest return on invest times, process engineers are - for the first time - able to create closed-loop control and real-time adaption of the mixing process resulting in an ultimate gain. Partner with MonTech today to adapt online testing technology for your mixing...

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MonTech ONLINE TESTING CELL SYSTEMS Automated testing system for mixing line integration MonTech is the world’s leading manufacturer of integrated rubber testing systems. With more than 30 years of engineering experience and 100+ fully automated Testing Cells installed, our testing solutions are designed for the specific testing and integration requirements for each customer or mixing line type. Based on MonTech’s field-proven automation technology, the Online Testing Cells are tailored for seamless integration into mixing lines and existing control and host-systems. All MonTech machines and...

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ONLINE TESTING INTEGRATIONInstruments and systems for Testing Cell integration: MonTech Online Testing Cells are equipped with a configurable set of standard devices for sample handling and preparation, with additional instruments to cover the individual throughput and test requirements for any mixing line. All instruments in Online Testing Cells are based on MonTech's reliable rubber testing instrument technology with each instrument adapted for seamless integration into any fully automated testing system. These adaptations include automatic handling accessibility for shorter handling times,...

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MonTech ONLINE TESTING CELL SYSTEMS ONLINE TESTING CELL System overview Online Testing Cells are state-of-the-art automated testing solutions that provide maximum efficiency and the shortest ROI times. By installing Testing Cells at the production line, manufacturers can achieve maximum throughput, tighter quality control, decreased laboratory overhead, and less scrap. Rugged and reliable technology: MonTech Testing Cells are a complete batch release laboratory on a 2.0 by 2.3 meter footprint. With flexible configuration, Testing Cells contain each element of the laboratory QC process within...

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AUTOMATED SAMPLE PROCESSING AND TRACEABILITY Online Rubber Testing Cells feature robotic automation and eliminate the need for any operator involvement. By applying robotics, administrators can monitor and control production in real-time without needing a separate QC or testing laboratory. All necessary steps to process the raw slab are selected according to the control plan and automatically executed by the Testing Cell. This includes: - Receiving, detecting and aligning of the raw slab - Washing, conditioning, cooling and drying of the slab - Slab measurement, nicking and volumetric cutting...

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MonTech ONLINE TESTING CELL SYSTEMS System layout DETAILS Since the introduction of the Online Testing Cell by MonTech in 2010, these automated systems are now considered to be the market leading solution for mixing line quality control in the rubber industry. The front of the Testing Cell structure contains the access points for each of the four instrument compartments. The adjacent side contains the main control panel, and the safety-locking maintenance access door. The top of the Cell is outfitted with the in-feed conveyor, sample in-feed chute and the status signal tower. Infeed conveyor...

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Cell interior and COMPONENT LAYOUT The interior of the Testing Cell is designed to keep safety, easy accessibility, and quick serviceability in mind: Two large walk-in maintenance safety doors are installed on either side of the Testing Cell. This allows for quick and easy access to all Cell internal modules and components. Uptime for Online Testing Cells can be in the range of >99.8%. The modular design allows for different sub-systems to be added or removed in minutes, guaranteeing maximum uptime and availability of the system. Below is an example of a typical Online Testing Cell found on a...

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The backbone of each Online Testing Cell is a modern multi-layer software design, aggregating the Test Cells into several functional units for quick connectivity and future adaptability. The proprietary Testing Cell software architecture consists of a Cell Master PLC for all high level tasks and a 19" touch panel for direct feedback. MonCell software consistently coordinates all instruments, Testing Cell systems, and test configurations. The Cell programmable logic controller (PLC) monitors all control tasks and critical safety functions in real time. All testing Cell communication is based on...

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Robotic hAndling System Robotic handling solutions are integrated into every Online Testing Cell, achieving the high productivity rates for the testing process. The core component to each Testing Cell is a highly precise, reliable and extremely fast 6-Axis robot system. The robot is positioned in the center of the Testing Cell with access to all critical sampling areas and testing sub-systems. In order to excel with the large variety of tasks, the robot is equipped with a multi-functional handling arm. Processing and handling samples is done with multiple sets of mechanical grips, combined with...

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All MonTech Werkstoffprüfmaschinen GmbH catalogs and technical brochures

*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.

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