Efficient dosing processes: Control vs. regulation - what makes the difference?
27 Feb 2025, 11:00:00
In industrial dosing processes, controlling the quantity dispensed is crucial for quality and efficiency. But how can you ensure that dosing is always precise? We compare four different control models and show how the Walther Valve Controller (WVC) drastically reduces the integration effort.
Figure 1 (🇬🇧 5): Classic PLC control without feedback The valve is opened for a fixed time ⏱️, but the actual quantity discharged can fluctuate - e.g. due to changes in pressure or viscosity. Without measuring the actual discharge quantity, process reliability remains limited.
Figure 2 (🇬🇧 6): PLC with volume flow meter for process evaluation (IO/NIO) Measuring the discharged quantity is possible, but involves a high level of integration effort (additional hardware, software adaptations, calibration and fine adjustment).
Figure 3 (🇬🇧 7): WVC control with volume flow meter for process evaluation (IO/NIO) Low integration effort via plug-and-play: Automatic calibration and compensation of dead times facilitate commissioning. The volumetric flow is controlled directly via the WVC, without complex PLC adaptations.
Figure 4 (🇬🇧 8): WVC as a control system The highest level of process control: regulation instead of control! The WVC dynamically adjusts the valve opening time to ensure a constant discharge rate - regardless of external influencing factors such as pressure or viscosity fluctuations.
Conclusion: If you want process reliability with minimum effort, there is no way around a solution with the WVC!
Weitere Beiträge
Employee in focus: Kai-Uwe Garthe
Today we would like to introduce you to Kai-Uwe Garthe - our Sales Manager at Walther Systemtechnik! Kai-Uwe has been part of our team for just over a year and brings his passion for communication and direct customer contact to his work every day.What makes his job so exciting? For Kai-Uwe, the greatest attraction of his work is its versatility. He is particularly enthusiastic about communicating with customers and building long, successful partnerships. It's exciting to see how a conversation and an idea turn into a functioning system - and you get to know lots of interesting companies and people in the process. What motivates him? Kai-Uwe has the clear goal of constantly developing himself further and thus continuously advancing the company. His greatest strength? Kai-Uwe is characterised by his ability to work in a team, communicate and always have a customer-friendly attitude - qualities that are simply essential for his role as Sales Manager. And in his free time? When he's not in the office, Kai-Uwe likes to spend his time playing football or with his family and friends - the perfect balance to his working day. His advice to his younger self: ‘First do an apprenticeship and then a dual study programme or a bachelor's degree at a university of applied sciences.’ Kai-Uwe, it's great to have you in the team!
Price on request
9 Monate voller Engagement – Wir sagen Tschüss, Ayse!
Thank you for 9 months of commitment, Ayse! After 9 months, it's time to say goodbye to our intern Ayse, who completed the practical part of her retraining programme with us. During this time, she enriched our team with a great deal of commitment and dedication - and we really appreciated her motivated nature!Dear Ayse, we would like to thank you for your great work and wish you every success for the future - both professionally and personally! Perhaps our paths will cross again!
Price on request
Team spirit, action and shared experiences!
At Walther Systemtechnik, we not only focus on innovation and precision, but also on working together! This year, we have planned many exciting after-work events for our employees - and their families are also very welcome. We kicked things off in February with an energetic indoor soccer tournament. After some exciting matches, we rounded off the evening with a convivial meal together.A big thank you to everyone who took part - we are already looking forward to the next events! Here are a few impressions from the evening!
Price on request
Employee in focus: Sebastian Meyer
Today we are introducing you to Sebastian Meyer - our dedicated Team Leader Internal Sales at Walther Systemtechnik! He has been an important part of our team since 1 March 2019 and, with his structured and solution-oriented approach, ensures that our internal processes run smoothly.What makes his job so exciting?
No two days are the same! New challenges and unexpected events ensure that there's never a dull moment - and that's exactly what Sebastian loves about his work.What motivates him?
Quite clearly: his team and the goal of constantly developing Walther Systemtechnik further. Working together on solutions and driving the company forward is his greatest driving force.His greatest strength?
Sebastian is a real problem solver! He has an impressive flair for finding the right information and learning from the past to make the best decisions for the future.And after work?
Then it's all about football, skiing and his family - the perfect balance to his varied working day.His advice to his younger self?
‘Do it exactly the same way! I'm happy with my life and have found my place in it.’Sebastian, we're glad to have you in the team!
Price on request
Efficient dosing processes: Control vs. regulation - what makes the difference?
In industrial dosing processes, controlling the quantity dispensed is crucial for quality and efficiency. But how can you ensure that dosing is always precise? We compare four different control models and show how the Walther Valve Controller (WVC) drastically reduces the integration effort. Figure 1 (🇬🇧 5): Classic PLC control without feedback
The valve is opened for a fixed time ⏱️, but the actual quantity discharged can fluctuate - e.g. due to changes in pressure or viscosity. Without measuring the actual discharge quantity, process reliability remains limited.Figure 2 (🇬🇧 6): PLC with volume flow meter for process evaluation (IO/NIO)
Measuring the discharged quantity is possible, but involves a high level of integration effort (additional hardware, software adaptations, calibration and fine adjustment). Figure 3 (🇬🇧 7): WVC control with volume flow meter for process evaluation (IO/NIO)
Low integration effort via plug-and-play: Automatic calibration and compensation of dead times facilitate commissioning. The volumetric flow is controlled directly via the WVC, without complex PLC adaptations.Figure 4 (🇬🇧 8): WVC as a control system
The highest level of process control: regulation instead of control! The WVC dynamically adjusts the valve opening time to ensure a constant discharge rate - regardless of external influencing factors such as pressure or viscosity fluctuations. Conclusion: If you want process reliability with minimum effort, there is no way around a solution with the WVC!
Price on request
Employee in focus: Tom Oswald
Today we would like to introduce you to Tom Oswald - our Sales Manager at Walther Systemtechnik! Tom has been an important part of our team since 1 May 2020 and is shaping our customer relationships with his expertise and commitment. What makes his job so exciting?
Tom loves the daily dialogue with our customers, whether in person or on the phone. He finds factory tours at our customers' sites particularly exciting, as he can experience the diverse applications of our portfolio up close - from primary moulding and forming to highly automated assembly systems. There are always new challenges and the opportunity to help develop solutions for new technologies - a perfect mix of variety and innovation. What motivates him?
Tom is particularly motivated by the team spirit, finding solutions together and the satisfied customers. When everyone pulls together and the best possible solution is found for the customer in the end - that's his greatest reward! His greatest strength?
Tom has a real gift for communication and is a master of troubleshooting, especially when it comes to complex processes. No problem is too big for him - he stays calm and always finds a solution. And in his spare time?
Tom likes to get creative as a DJ and ensures that people experience emotions through music. He also likes to be active in the gym or playing ball sports and loves doing sports. His advice to his younger self?
‘Life isn't always easy and sometimes it feels unfair. But it's important not to give up and to always keep your goal in sight. Success is a staircase, not a door!’ And what does Tom say about his career?
‘I would want to relive my career 1:1 in exactly the same way. Maybe I would give English more importance in my school days.’Tom, we're proud to have you in the team!
Price on request
Dosing technology meets Christmas magic
In our new video, we show you how our technology even shines in the Christmas bakery. Marvel now at how sweet dosing technology can be - and discover how we build a gingerbread house at Walther!
Price on request
35th anniversary - Thomas Danz
35 years with Walther Systemtechnik - a reason to celebrate! Today we would like to honour our colleague Thomas Danz, who has been part of our team for an impressive 35 years. Thomas started his career with us in design and project planning and later moved to the field, where he proved his expertise and customer focus. Today, he is a trusted member of our technical office staff. His extensive knowledge, experience and dedication make him a valuable member of our team. Dear Thomas, thank you very much for your commitment, your reliability and the many years you have helped to shape Walther Systemtechnik. We look forward to many more successes together!
Price on request
Ready, steady, go: let's start the second day of Lubricant Expo ...
Our team at Lubricant Expo North America is ready to help you find solutions for reliable manual and automated lubrication processes and answer your questions about the transfer, dispensing and application of lubricants in manufacturing.To talk about your specific needs, visit us at booth 225. Let us explore options and discuss concepts that meet your unique requirements.
Price on request
Hardened and ready for use ...
The spray valves of the WSV series are designed for a variety of applications in a wide range of production areas. When manufacturing the valve components in our company, we therefore consistently rely on protective processes such as potting. This process offers comprehensive protection of the electronic components against mechanical influences, moisture, contamination, extreme temperatures and thermal fluctuations.The WSV valve heads shown here were recently encapsulated with a high-quality two-component polyurethane resin. After curing, the resin reinforces the mechanical strength and ensures functionality and durability so that our valves can reliably perform their tasks even under the toughest conditions.
Price on request
Specialising in the lubricant industry: Lubricant Expo North America 2024
In a few weeks, from 19 to 21 March 2024 to be precise, Lubricant Expo North America will open its doors. This event is dedicated to the lubricant industry and presents itself as a unique platform that connects solution providers directly with a diverse group of end users and the entire chemical and equipment supply chain.
As specialists in the field of dosing and application of lubricants, we are looking forward to our participation with great anticipation. Our expertise covers the entire application process - from supply, transfer and preparation to precise dosing and dispensing. At Lubricant Expo, we offer an effective link between the diverse range of lubricant producers and the needs of users and end customers.
Visit us and discover how our solutions are helping to revolutionise lubrication applications and improve both the efficiency and reliability of application processes. We are particularly pleased to have Chris Ludwig from Airflo Equipment with us, who shares our passion for innovative fluid technologies. Don't miss this opportunity to discuss with us the latest trends and the future of lubricant application. We look forward to welcoming you in person!
March 19 - 21, 2024 / Huntington Place - Detroit, Michigan / Booth 225
Price on request
Lubrication of rolling bearings: Project completed ...
We have developed an advanced lubricant application system for rolling bearings that precisely addresses the challenges of component lubrication. Through the use of pulse valves, the system offers a pinpoint solution for component lubrication requirements, especially for small batch sizes with a high number of variants. It has been designed to enable fast and efficient adaptation to different production needs in bearing manufacturing by integrating automation, low set-up effort, recipe management and process control.
Flexibility and adaptability: The system allows quick adaptation to different bearing dimensions and types by simply changing the gripper jaws.
Automated processes: The manual insertion of the rolling bearings is supplemented by a fully automated process that includes component pick-up, alignment and lubricant application on one or both sides, as well as component removal. This ensures consistently high quality and reproducibility.
Recipe management: The ability to store and recall lubricant recipes and application programmes specific to different bearing types not only improves production efficiency, but also ensures that each bearing type is treated according to its particular requirements.
Process control: Integrated monitoring functions monitor and ensure precise lubricant application, ensuring accurate dosing and high process reliability.
Price on request
Professional exchange: training successfully completed with our Hungarian partners
We would like to express our gratitude to our Hungarian partners for their active participation and valuable input during the three-day intensive technical training, which covered both theory and practical application. We would like to express our gratitude to our Hungarian partners for their active participation and valuable input during the three-day intensive technical training, which covered both theory and practical application. We would like to express our gratitude to our Hungarian partners for their active participation and valuable input during the three-day intensive technical training, which covered both theory and practical application. Their dedication and expertise were evident and greatly contributed to the success of the meeting. We appreciated the chance to improve their understanding of our latest dispensing and application technology and strengthen our teams' bonds through experience sharing. We anticipate continued knowledge sharing and mutual learning in the future.
Price on request
Pump system for highly abrasive thermal paste ...
This pump system is a real powerhouse. It is exactly the right choice when it comes to supplying demanding media. As a customised solution, it is characterised by an application-specific design and has been specially designed as a tandem solution for the uninterrupted delivery of highly abrasive thermal paste in order to optimally meet the basic requirements in the growing field of electronics and PCB production.
The integrated homogenisation ensures continuous mixing of the rapidly separating medium. To ensure the accuracy of the media supply, a downstream gear flow meter was also integrated to monitor the volume flow. The result: constant delivery, precise dosing and increased efficiency in the production process. Incidentally, the heat-conducting paste is applied using a hand-guided outlet valve.
Our team has worked hard to develop a solution that fulfils the highest requirements. We are all the more pleased with the result, which offers real added value in terms of reliability and performance.
Price on request
The Walther Pulse Valve WPV: Innovative evolution of process technology ...
Precise dosing without component contact: Pulse valves represent an excellent solution for dosing a variety of viscous media. Through the repetitive and accurate dispensing of drops, very small quantities can be discharged at high speeds without compromising precision. Therefore, pulse valves are particularly suitable for applications that require high speeds, such as in mass production. In this context, even hard-to-reach and uneven component geometries are rarely a problem. However, the need for a usually complex control and programming presents significant disadvantages, such as associated high acquisition and commissioning costs, as well as an increased potential for errors. To minimize the costly complexity and make this type of media application even more efficient and user-friendly, we have developed the Walther Pulse Valve WPV.
Technological sophistication and integration: The WPV pulse valve is characterized by an optimized design that not only allows for a very small footprint but also incorporates advanced technologies for control, monitoring, and process evaluation. This enables a cost- and time-saving system integration without additional control technology, software, or programming. The motto "parameterize instead of program" extends from commissioning to process monitoring, offering additional possibilities to control and evaluate additional peripheral elements without overarching control.
Access to the valve's own dashboard is easily done via a web interface, providing extensive new options with remote parameterization and diagnosis. Additionally, multiple parameter sets can be stored, and process variables documented. Software add-ons also offer flexibility for future challenges. Other features include a pressure sensor, a valve heating system with temperature control, as well as analog and digital connections for comprehensive connectivity. Remarkably, the fully electric operation eliminates the need for compressed air lines, further reducing integration effort and space requirements while lowering operating costs.
Overall, the WPV impresses with well-thought-out functions and offers a high level of process control, positively impacting process capability, overall equipment effectiveness (OEE), and product quality. Thus, the WPV pulse valve represents a groundbreaking development in dosing technology: the combination of contactless material application and innovative features opens up new possibilities for efficient, highly automated production processes.
Price on request
Successful training of our Polish sales partners
Our sales partners from Poland were welcomed with pleasure. During their visit, they had the chance to try out some of our latest products, including:Our valve controller regulates a wide range of electrically and electropneumatically controlled spray, pulse, and metering valves from Walther Systemtechnik GmbH, as well as many conventional valves. It also evaluates valve peripherals such as sensors and actuators attached to the valve.The smart and purely electrically driven pulse valve enables cost- and time-saving integration without additional control technology, software, or programming.A series of pressure containers is available for providing and conveying liquid media. These containers come with integrated controls for the agitator, level sensor, and process valve.Our Polish guests tested these novelties in detail during a two-day technical training course and were convinced of their advantages. We appreciate the visit, the great interest, and the lively exchange. We look forward to seeing you next time!
Price on request
World Savings Day
Saving efficiently is not just about money. Optimizing resource usage can lead to greater achievements and cost savings. Therefore, process monitoring is always given special attention when developing new Walther products. Whether it's a pump system, valve controller or smart application valve, integrated monitoring functions provide a comprehensive overview of the running processes of your fluid application system.By using pressure monitoring,
as demonstrated in the video featuring the Walther ValveController WVC, you can detect and correct quality problems at an early stage, reducing scrap and rework and resulting in cost savings.- Detect and correct errors in the production process early to reduce downtime and increase availability. - Optimize processes and use resources more efficiently. - Make data-based decisions to improve the overall process. Process monitoring can help improve quality and efficiency in production, increase productivity, and reduce costs. It makes a significant contribution to increasing a company's competitiveness.
Price on request
Simple trick for difficult containers
The issue has been resolved.Recently, we faced a minor problem when we received a new product delivery. One of the containers had a unique feature - a collar at the upper edge that tapered the opening, similar to a paint can. This presented a small yet significant challenge as it made inserting the follower plate of our conveyor system into the container more difficult.In such a scenario, transferring the contents into a standard container would be a suitable solution. However, a more efficient approach is to cut open the top of the container. It is crucial to ensure a smooth and burr-free separation of the material. This can be achieved easily with the help of a common household item found in nearly every home - a can opener. If you ever find yourself in a similar situation, keep this handy trick in mind!
Price on request
Efficient drum emptying for greases and lubricants
Our pump systems allow for the direct transfer of grease and highly viscous lubricants from the barrel. We offer a variety of options for easy and reliable emptying of OEM containers. As experts in handling viscous media, we understand that many projects face unique challenges. Therefore, in addition to our proven standard pumps, we also provide special solutions tailored to specific needs. An example of such a solution is the integration of a degassing system. Degassing is crucial for many media as it protects downstream components and ensures smooth, reproducible, and precise subsequent processes by detecting and removing unwanted gas inclusions.Integrated degassing offers benefits such as
monitoring the medium for gas inclusions and automatic ejection,
minimal loss of medium (only the contaminated portion is ejected),
and continuous release even during degassing and container changes. • Capturing production-relevant process parameters • Improving process capability and Overall Equipment Effectiveness. If you require further information on conveying viscous media, container emptying systems, or specific special solutions, please do not hesitate to contact us...
Price on request
Motek post-processing
The Motek Messe has ended, and now it's time for follow-up work. Our team is grateful for the overwhelming interest, engaging conversations, and positive feedback from all our visitors. We are confident that our products and services have left a lasting impression on our audience. We eagerly anticipate the next event, as we continue to showcase our expertise and innovation in the industry.
Price on request
The secret behind our glowing shoes
Frequently asked question about Motek: What's the story behind the glowing shoes you're all wearing at the trade fair?Our answer: The shoes are a brilliant example from the field of adhesive applications. Gluing processes play a key role in shoe production, as they enable efficient production and at the same time offer increased flexibility in the design process. One prominent application is bonding shoe upper materials to the sole to ensure the durability and functionality of the shoe. In addition, bonding techniques are used to realise a clean and professional interior of the shoe and to increase wearing comfort. The inner lining, footbed and padding are professionally bonded to guarantee maximum comfort.Adhesives are not only used for reinforcements and connecting elements such as buckles, eyelets or zips, but also for decorative elements such as rhinestones, metal applications and artificial leather applications.As specialists in the dosing and application of viscous media, we offer customised solutions for the precise application of various adhesives. We guarantee the repeatable and even distribution of adhesives in the right quantity, whether in the form of areas, dots or lines - whether felted, sprayed or powdered. Our application-specific solutions are process-safe and efficient, which optimises the manufacturing process of footwear, for example, in automated production lines.
Price on request
Visit us at the Motek: Booth 5413
Explore a wide range of solutions for dosing and applying viscous media that can significantly improve your work processes in terms of productivity, efficiency, and safety at the Motek Messe's final day. Our modular system for applying adhesives, glues, silicones, polyurethanes, acrylates, epoxies, or gap fillers can be customised to your specific needs with various sizes of adhesive pumps, piston dispensers, and outlet valves. We offer a wide range of adhesive pumps, piston dispensers, and outlet valves in various sizes to provide tailored solutions for adhesive applications in the 1K and 2K range, precisely meeting your needs.Take the opportunity to experience our solutions firsthand through personal conversations. Join us at booth 5413 in Hall 5 and let yourself be inspired!
Price on request
Motek 2023
Our colleagues are eagerly awaiting your visit at booth 5413 in Hall 5 of the Motek Messe trade fair in Stuttgart. We will showcase cutting-edge innovations and tried-and-true solutions for supplying, transferring, and applying liquid and viscous materials, all designed to elevate your production efficiency to new heights.
Price on request
Three in one: Experience our small tin cans at Motek
These tin cans are charming! They have a diameter of just under 4 cm, but as the saying goes, it's what's inside that counts. They showcase our valve technology at its best, demonstrating three of
the most important application methods for viscous media in one small package. And, to top it off, you'll get to hold one in your hand. This is a reminder for those seeking innovative dosing and application technology for viscous media.
To learn more, register for free entry at this link (https://lnkd.in/ektQrxBf) and visit us at Motek from October 10th to 13th. We will showcase products and both manual and automated applications that can enhance your production. Please mark the date in your calendar and share it with friends and colleagues. We look forward to seeing you at the trade show!
Price on request