|Process Control System
Our Integrated Process
Control System (IPCS), produced exclusively by
ECI, is a fully integrated, fully computerized, process
control system originally designed specifically for refrigerant
bearing appliance manufacturers. ECI has since designed
Integrated Process Control Systems for appliance manufacturers
and other industries as well. By putting the control in
your hands, the Integrated Process Control System improves
both your quality and production efficiency.
The modular design of the Integrated
Process Control System allows you flexibility, from a single
test station to a total solutions system. Your options may
include Integrity and Helium Leak Test, Single-Point Evacuation
and Charge, Automatic Run Test, Final Leak Test, Key Component
Verification, Control Panel Testing, Customer Watchdog,
Conveyor and Material Handling Controls, and Network Installation.
Our Integrated Process Control
System supports all major networking systems, with universal
database compatibility. Our key component verification guarantees
the right match for parts, every time. Our evacuation and
charge stations provide full refrigerant accountability.
Our process control software is fully customizable, and
comes with a lifetime warranty. We're the only ones who
can offer you a testing and information collecting system
that is there every single step of the way. And so are we.
The following is an example
of an Integrated Process Control System on for an HVAC assembly
1. Key Component Verification
Station - The Key Component Verification (KCV) Station
eliminates the possibility of incorrect unit assembly,
guaranteeing the right match for designated parts and
sub assemblies, every time. As a stand-alone station,
or as an addition to any other Integrated Process Control
System station, KCV is invaluable. All key components
are verified against the bill of materials, item by item.
Stations may be positioned throughout the assembly line,
wherever components are installed. Component serial numbers
are then linked with unit serial numbers for complete
manufacturer tracking. This module of the Integrated Process
Control System allows the operator to systematically verify
that the correct parts have been installed in the correct
units - making defect reduction, warranty tracking and
supplier recall assistance easier and more accessible.
2. Integrity and Helium
Leak Test Station - A refrigerant leak at the end
of your line means lost time and money. The Integrated
Process Control System has a better way to test by utilizing
the ECI Integrity & Helium Leak Test Station. These
computer-based stations may be located in coil sub-assembly
areas, in addition to the final assembly line. The sequence
of operation is computer-controlled, and parameters are
model-specific. The leak detector calibration is computer-verified
prior to each or a user selectable number of cycle(s).
If a leak is detected, defect codes are entered to identify
the joint and the responsible brazer. All in a process
that satisfies the documentation requirements of UL. Thus,
this station of the Integrated Process Control System
eliminates the cost associated with reworking a unit to
repair a leak after refrigerant charging by identifying
leaks prior to charging.
3. Single Point Evacuation
and Charge Station - The single point Evacuation and
Charge Station eliminates the need for a maintenance-intensive
evacuation pump carousel - saving you space, time and
money. Our Integrated Process Control System enables each
operator to handle multiple stations at a time, efficiently.
The units are evacuated to a customer-configurable vacuum
level, vacuum-decay checked and automatically charged
- all in one hook-up. The computer-based system maximizes
production efficiency by guaranteeing correct evacuation
and charge weights.
4. Performance Run Test
Station - The Integrated Process Control System's
computer-based Performance Test stations have been developed
for a number of products, from refrigerators to furnaces,
from heat pumps to washers and dryers. A computer-controlled
sequence of operation eliminates operator dependency.
All collected data is automatically written to the Integrated
Process Control System's database by serial number. Highly
reliable, entirely adaptable. This station is custom-built
from design to installation to test selected functions
of your unit.
5. Final Leak Station
- Your assurance that no leaks have occurred during the
running and the completing of the manufacturing processes.
The Final Leak Test, like all of the Integrated Process
Control System stations, verifies that the unit has successfully
passed all previous Integrated Process Control System
tests. Leaving nothing to chance.
6. Packout- The ECI Watchdog
- The Watchdog is your guarantee that your customer receives
the best quality product that you can provide. An all-encompassing
crosscheck through all Integrated Process Control System
processes, the Watchdog is the final assurance that each
unit has passed all previous quality tests. No defect
gets through the Integrated Process Control System. Electrical
interlocks prohibit final packing and shipping until all
tests have been passed. That gives your customer a consistent
level of quality.....guaranteed.
If you would like to learn more about
how ECI can help your plant implement an Integrated
Process Control System, please request our free "Revolutionize
Your Assemly Line" CD Set and Ranking Technology Providers
us about your plant's needs,
or call 901-854-2123.