Visualization and control of the galvanizing process
in CVP Galvanika s.r.o.

CVP Galvanika s.r.o. in Pribram was founded in 1992 by Austin Cenkner, Ivan Vancura and Jan Pajtai. Production started the following year with seventeen employees. CVP s.r.o. has always made their production technology a high priority. Thanks to this , the company is able to achieve the highest quality required by the customers. CVP s.r.o. has become a strong supplier for the automotive industry since its beginning. Currently, the company provides metal surface finishing for more than 350 different customers. The largest customers of CVP s.r.o. are American General Motors and Ford, German Volkswagen and Czech Skoda.

Picture of the galvanizing process

Contol system

A complete reconstruction of two galvanizing lines was carried out in 2007. The reconstruction also included implementation of the new SCADA-based control system. SCADA/HMI system Reliance along with a Tecomat NS950 PLC device were chosen for reliable control of the galvanizing lines. The reconstruction of the galvanizing lines and the installation of the new control system were carried out by Czech company AITEC s.r.o.

The new control system of the galvanizing lines allows:

• Unmanned operation of both galvanizing lines with optional settings
• Control the dosing of shines during the process of galvanization
• Dissolving and filterin zinc
• Removal of Carbonates from the Zn-Ni bath by using the lyophilization

The existing system was replaced by the Reliance SCADA/HMI system during the reconstruction. The whole SCADA-based control system consists of a Tecomat NS950 PLC, a control computer with Reliance Runtime Control software which is located in the control room and operator panel with large touch screen located by the galvanic lines. All these parts of the control system are connected via Ethernet. Authorized personnel can control a whole process of galvanization over several transparent visualization windows created in Reliance. Galvanization can be controlled not only from the control room but even from the operator panel. Important data (e.g. galvanized products per hour, changes of the production process, occurred alarms and events) is saved to the Reliance database during the process of galvanization. Obtained data is used for further processing. Reliance also provides printing of reports and protocols, failure diagnostics and log changes during the process of galvanization.

As a result of the reconstruction, the production capacity has been significantly increased and the galvanizing process' technology is more advanced.

Example of a visualization window

Visualization of the galvanization line