Blown Film Extrusion Internal Bubble Cooling and Non-IBC

3rd Generation IS-IBC1 Internal Bubble Cooling Control System (patented)

The third generation IBC controller from D.R. Joseph, Inc. incorporates lessons learned from 20 years of supplying IBC control systems to the global blown film extrusion market. The new system incorporates a smaller size, lower power consumption, fewer installed parts, the same high performance and new features that make overall operation even easier than before! This new unit focuses on automated adaptability to the application of internal bubble cooling and automated width control. Power consumption for the system has been reduced by approximately 50% over our previous systems.

Flexible Configurations
Regardless of the available space on multi-layer extrusion lines, there is anIS-IBC1 configuration that will fit the bill. The new ALL-N-ONE panel requires 27% less volume over our previous system panel (shipping weight has also been reduced by 40 pounds). A new MODULAR configuration has been added for an 83% reduction in volume. We also support a “built in” or OEM version to minimize required space to an absolute minimum.

Multiple Operator Stations
The new 3G IBC even allows for multiple operator stations as shown below:
In the ALL-N-ONE configuration (shown right), all IBC components are mounted within a 15 inch by 15 inch panel including easy access power connection, a new 90% efficient power supply (replaces the previous 70% efficient power supply) and new 5 port Ethernet modem/managed switch. A new configurable management beacon lamp is also supported to allow visual alert to management for of a variety of conditions including non-standard use of the system and internal or external faults.
	For installations extremely tight on space, the modular design allows the main control panel to be mounted up to 20 meters (65 feet) away with the very compact touch screen panel mounted in a variety of configurations.
Finally for a totally integrated look, the “built in” or OEM configuration provides the same point to point wiring configuration as the ALL-N-ONE and modular configurations but allows all the parts to be efficiently mounted inside the main control station. Alternatively, the hidden IBC control components can be mounted up to 20 meters away from the location of the IBC system touch screen.
Improved Sensor Wiring
One of our main design objectives was to simplify the sensor installation process making for a much easier process for the installer. We moved all the functionality of the notorious blue boxes into the main controller. As a result, the blue boxes are replaced with a simple to mount eight-port junction box with round twist-on cable connectors.

The connectors that mount to the 8 port junction box are a new design that allows easy passage through conduit with an outside diameter of 0.65 inches (16.5mm). We also eliminated the master IBC port requirement, thereby eliminating the need to arrange the sensors in a particular order. To eliminate problems with electromagnetic interference (EMI), the sensor cables are double shielded.
New Optional Smaller Touch Screen
Another cost saving option is the new 4 inch TFT full color touch screen. It has the same brightness as the 6 inch TFT screen and can be specified on all of our systems except systems with manual or auto cage control.

100% Touch Screen Control
Cost reduction was another objective, and our main effort on this front was the main control panel. As mentioned earlier, we reduced the size by nearly 30%, but we eliminated many of the old discrete components that were closing in on end-of-life.

As a result, we’ve been able to deliver an IBC system with single point control for IBC, Blowers, Sizing Cage and a host of other options. Using popup window techniques, the operator sees only what he needs to see to get the job done.

Ducting Failure Detection
Air flow restrictions make up more than eighty percent of the service calls we receive at DRJ. Restrictions can be anything from a clog to a collapsed hose to a dirty air filter. Regardless of the issue, air flow to… or… from the bubble is impeded and maintenance personnel find it difficult to focus on something as mundane as ducting. This system will actually point them to the specific air flow path and can even detect improperly installed components.
Automatic Valve Calibration
Another maintenance issue that is often overlooked is the periodic calibration of the bladder valve. The system will now calibrate the valve as required without the operator having to make any special steps. This eliminates the need for maintenance to manually adjust the system when there are subtle or significant changes to the die or air flow path.
Automated Assistants
The IBC system has installation requirements that are often overlooked by a less-experienced commissioning engineer. For instance, getting the layflat sensors in the proper position to handle all possible bubble sizes or setting up the bubble break detector distance or establishing the final blower ratio. We’ve added new features that assist or automate the process with guidance details so less time is spent getting these features properly commissioned.
Field Configurable Features
The numerous new features can give our existing customers a headache when strict operating procedures are in place. This system allows each user to decide how much of the automation to implement. For instance, manual valve calibration is still supported. The system can be configured to automatically calibrate the valve when needed or it can be configured to skip automatic calibrations. Going further on the valve calibration configuration, the system can be setup to calibrate based on excessive down time, number of days since last calibration, detected air flow anomalies or number of startups.

Reverse Compatibility
Whenever we produce a new system, we do everything possible to protect our existing customers’ investment. The 3rd generation ISIBC1 is no exception. We’ve made the 3rd generation software so it can run on previously installed 32 bit systems. This means that adding automatic valve calibration only requires replacing the touch screen and installing electronic Magnehelics (if required - we’ve been shipping systems with electronic Magnehelics for more than a year now). Please note that 8 bit systems cannot be upgraded unless the 8 bit controller is replaced with our 32 bit controller. DRJ does offer a core value on the 8 bit controller to reduce the upgrade costs.
Integration Enhancements
There is nothing more involved for the customer than to configure and validate data integration. Regardless of the integration level, the IS-IBC1 system can support it. It has five built in protocols (Modbus RTU, Modbus ASCII, Modbus TCP, Modbus UDP, Kundig PCD.2), and a wide variety of industry standard protocols enabled through an optional protocol converters. Through our new Ethernet modem, we now have four available Ethernet ports to connect to a variety of other devices without the need for an additional Ethernet switch.
Enhanced Layflat Calibration
As with our generation 2 IBC control system, the 3rd generation system supports layflat sensor calibration via a Kundig width bar through one of the available four Ethernet ports. Note that any Kundig width bars (FE-7) with an Ethernet enabled Measuring Bar Interface can be integrated into the IS-IBC1. Taking this another step, customers can have the option of sending a calibration value through protocol to the IBC system to calibrate the layflat sensors. This allows the customer to take advantage of a previously integrated web guide or gauging system that has a width output.
Economy Version
There are often times when a comprehensive solution is really more than the customer needs. As a result, we’ve added an economy version of the All-In-One configuration that provides the essentials of IBC and width control at a lower price point than the standard All-In-One configuration. Further, if the customer wants to later upgrade to the standard version with 6 inch touch screen, cage control and Ethernet modem, this can be done by the customer as a field upgrade. It is important to note that the economy version does not include the 5 port Ethernet modem which is required for remote diagnostics.

Additional Features
Bubble Break Detector – Automatically arms, resets and can be interfaced to just about any Programmable Logic Controller or computer. Layflat Deviation Alarm – Can be configured to detect holes when running master tubing rolls. Remote Control Operation – This feature allows you to control every aspect of the IBC system from across the plant, across town, or across the world. This function is designed mainly for integration purposes, but is also great to temporarily isolate any portion of field wiring when chasing down intermittent wiring failures. Multiple Monitoring Points – These are supported by the standard Ethernet connection port. Up to ten users can be connected to a single IBC system over a single physical connection. OEM (Original Equipment Manufacturer) Integration – This feature allows the IS-IBC1 to be fully integrated into any OEM extrusion line control system. Configurable Management Alert Beacon – This highly visible xenon lamp flashes based on a configurable set of parameters. The parameters allow management to be alerted whenever the operator operates the system in a manner outside standard operating procedures (for instance, running the system in manual layflat control when the SOP requires running in automatic layflat control) or when there is an internal or external fault.