Managing up to 80 units with Moretto’s ONE Wire

The evolution in conveying systems has pushed manufacturers in recent years to implement additional new features, such as pipe cleaning management for conveying regrind material, self-cleaning receiver filters, loading failure alarms and many others which, like the ones mentioned, have now become standard requirements for the conveying systems management.

The first answer to these needs from Moretto was ONE Wire 2 which, having reached the ambitious target of selling 10,000 units, now gives way to a new generation of management systems. Today Moretto is one of the few companies to be able to provide not only a management system for centralised installations, but a really comprehensive range of specific products. When the converter’s demand goes beyond the single three-phase system, Moretto offers, right from the start, a conveying system, pursuing the bay concept.

The ONE Wire series includes the EXA, ONE Wire 3 and ONE Wire 6 systems. Based, as every Moretto’s ranges of products, on the key principle of modularity, these solutions makes it possible to switch from one unit to the other by implementing a few simple and quick changes to the existing system, according to the converter’s needs. From two to up to six receivers, Moretto allows a three-phase conveying system to be configured with an integrated control unit and the ability to manage the entire system from one single station, thus creating a true network, making it possible to programme and monitor it from any point of it.

This system is called EXA, meaning “six” in Greek and considered in the Hellenistic culture the perfect number: the number of receivers manageable within a local network. The EXA system clients have a dedicated electronic board, developed to create a network of up to six clients, forming a mini-centralized system with only one vacuum unit. This solution, specifically designed for dosing systems with up to six components, is an integrated management solution for multi-material systems: gravimetric and volumetric dosing units, loss in weight blenders, drying systems with up to six hoppers and groups of processing machines. EXA features all the functions of a centralised system, without exceptions, and is therefore an open system which can be subsequently expanded, with no restrictions or problems.

When the number of machines grows, EXA can be upgraded to the ONE Wire 3 system: a minimum investment for the integration of a PLC, acting as a server, makes it possible to add new machines, up to 80 total client units.  Compared to the first generation systems, ONE Wire 3 features considerably enhanced management functions. In particular, the Dual Zone function allows for management of two suction units connected to a single sorting station, machine queue management and separate materials queue management. The user can manage the system through a double, keyboard-touchscreen central interface, choosing between the Master 300 control and the industrial wireless Master 600 control.

The ultimate expression in conveying system management is the Moretto ONE Wire 6 series, the evolved version of ONE Wire 3: it is one of the few systems available on the market today, which is capable of adapting to the plant status, detecting every possible change automatically. Thanks to the Vibe technology, ensuring superior performances through its self-adjustment function, ONE Wire 6 automatically sets up and optimizes the quantity of resin to be conveyed. In a conventional system, the operator is required to set the parameters for suction and pipe cleaning time manually: OW6 automatically detects changes in material type and on the feeding segment, adjusting the suction and pipe cleaning parameters instantaneously.  In turn the machines, connected to the desired pipe, recognize the new conditions and adapt and recalculate the necessary conveying time.

The OW6 server can manage up to a total of 80 linked units such as receivers, up to 8 suction units and manual and/or automatic sorting units.  The user interface consists of a 15” colour touch screen, including the instruction manual as well as a configurable program for precautionary maintenance and, as an optional, a Master 600 wireless controller, to be used for system supervision. 

Both ONE Wire 3 and ONE Wire 6 can be connected with Moretto’s Mowis integrated supervising system, and are equipped with Ethernet connection for remote assistance.