Automation

Автоматизация АСУ MixMaster

ACS MixMaster

PJSC Betonmash equips its products with automation, which takeы control of main technological processes of the equipment.

Tabs

Characteristics

Автоматизация АСУ MixMaster
PJSC Betonmash equips its products with automation, which takeы control of main technological processes of the equipment. The concrete-mixing plants by PJSC Betonmash are complete with basic functions, which provide fully automatic operation of the plant and collateral operations. On agreement with client the plant may be equipped with additional functions improving plant operation.

Late-model concrete-mixing plants with relay control system can be modified for using computer automation system. Existig relay scheme will demand minor modifications and installation of a PC connected to weighting equipment WE2110. For brief description of the software see below.

 

 

RELAY CONTROL SCHEME MODIFICATION
AUTOMATION+1C

MIXMASTER CONCRETE-MIXING PLANT CONTROL SOFTWARE MANUAL
 

Description of a baseline:

Baseline consists of a lower automation level (integral technical support for automatic concrete-mixing plant operation) and a higher level (gives the operator and other persons convenient access to the information and possibility to easily control processes at the plant)

Lower level:

- full automation of concrete-mixing plant operation
- many stored formulas
- high-precision batching system
- automatic and manual operation

Higher level:

- AI software
- user-friendly interface
- easy control of order sequence
- intelligent batching algorithms
- control of fulfillment of an order
- accounting documents preparation
- emergency alerts
- high-wear details status control
- component replacement planning
- maintenance records

Additional options:

- inventory control of materials
- product cost calculation
- electric power meter for consumed energy
- humidity measurement system
- installation of frequency converters
- chemical additives flow counter
- video surveillance system
- distributed monitoring and control system
- installation of load cells to cement silos
- platform truck scale

 Baseline, lower level

 - full automation of concrete-mixing plant operation. Automation based on an industrial PC lets an order to be fulfilled completely in automatic mode – from batching to shipment. Reliable means of communication provide continuous communication of standalone elements. Full consumption records allows controlling its use. Up

 - many stored formulas. Version without a PC – up to 100 formulas. Version with a PC – more than 1000 formulas. Up

 - high-precision batching system. Load cells and weight indicators provide high-precision batching. All weight indicators pass state certification at PJSC Betonmash, which is confirmed with a record in the equipment test certificate. Thanks to using an intelligent algorithm the batching error is 1% for aggregates and 0.5% for cement, water and chemical additives. Components

Up

- automatic and manual operation. Operator’s workstation is equipped with a PC and an operating console. When automatic operation mode is selected the operator chooses current order on screen and gives a command to fulfill the order, then automation loads materials to the mixer and starts mixing. Automatic operation is possible without a PC. The main operation mode is automatic. Manual operation mode serves for testing of the mechanisms and their adjustment. Up

Baseline, higher level

- AI software. Software controlling concrete-mixing plant operation is based on an industrial PC and discrete I/O modules. The system is the leading software for controlling technological processes. Software functionality ensures reliable storing of all necessary data concerning orders and formulas as well as displays necessary information about current operation of a concrete-mixing plant. Up

 - user-friendly interface. Flexible and multifunctional graphical software tools ensure non-stop displaying of current concrete-mixing plant status and order fulfillment progress. User-friendly interface ensures easy information entry. Up

 - easy control of order sequence. User is granted a possibility to enter orders in respect of a client, formula, volume, truck number, destination. Besides user can modify order sequence. To start a mix preparation process operator just needs to choose a corresponding order and press the start button – the rest will be done by automation. Up

 - intelligent batching algorithms. PJSC Betonmash experts have developed special algorithms which increase batching accuracy and allow saving materials during concrete production process. Two-stage loading of batchers (coarse batching at the beginning and fine at the end of the loading). Automatically adjusted latency of inlet gate response relative to materials flow and dosage as against previous batching. Error compensation algorithm at batching phases (system minimizes batching errors of previous mixes by increasing or decreasing dosage during next mixes). These algorithms considerably increase the product quality and save consumable materials. Up

 - control of fulfillment of an order. Operator’s screen displays the status of fulfillment of the order, volume of produced concrete, measurement error. Moreover operator receives information about plant mechanisms status. Up

 - accounting documents preparation. The system automatically keeps records of materials consumption, which allows examining/printing information about a fulfilled order or orders over a certain period. The system stores data for a year. Up

 - emergency alerts. Displaying information about failures lets respond to a breakdown or malfunction early. This lets a plant’s owner avoid considerable expenses and equipment damage. The system checks certain conditions, when plant operation is impossible, i.e. no cable tension, mixer’s inspection hatches are open etc. In this case automation displays a failure message. After the cause of malfunction has been removed, alerts are automatically cancelled. Up

- high-wear details status control. The system keeps record of remaining life of certain details as the orders are being fulfilled. When life-span of a detail approaches critical level, operator receives a message reminding to take measures (replace or repair a detail). After the replacement or repairing is over user may cancel the alert, confirming that the works have been completed. Up

- component replacement planning. Basing on plant operation parameters (average volume of concrete produced per day, average mix speed of 1 cub. meter) information about replacement age of a detail during a specified time (nr. of months) is available. The information is useful for detailed calculating of profit and costs. Up

 - maintenance records. To ensure on-time maintenance the system has a function of alerting the user about necessity to carry out routine maintenance (monthly servicing). After servicing is complete the user confirms it, after that information about date and time of maintenance as well as user information are automatically recorded into the database. Up

Additional options:

 - inventory control of materials. User keeps record of arrival of materials to the depot, stating type of the material, volume and price. The system automatically checks materials availability at depot by calculating material demand for current orders and deducting this amount from the total amount at depot. Operator is promptly notified of materials running out at depot. Up

 - production cost calculation. After the order is fulfilled cost accounting of concrete production based on materials prices and  entered overhead costs is automatically carried out. User is granted information about cost of the orders fulfilled as well as monthly costs. Up

 - electric power meter for consumed energy. Installation of a power meter allows monitoring electricity consumption at operator’s console as well as automatically adding electricity costs to the production costs of the produced concrete. For this purpose electric power supply is connected through a special record box with a cutout switch, where a three-phase power meter of  active-reactive energy is installed. The meter is connected to a PC, providing operator with up-to-date information. Up

- humidity measurement system. This option allows correcting volume of water and aggregates (churning stone, gravel, sand etc.) batched according to the formula with regard for their humidity (humidity value is added automatically or regularly added manually subsequent to the results of laboratory measurements). As a result automation is able to stabilize cement-water ratio in the concrete mixer according to the humidity meter and hence to increase the quality of produced mix as well as to decrease water consumption during concrete production. Humidity and temperature sensors (humidity readings depend heavily on environment temperature) with metering module are used. Up

 - installation of frequency converters. Installation of a converter to the helical conveyer motor lets automation batch material more precisely by decreasing feeding speed after major part has been fed. Components

Up

 - chemical additives flow counter. Batching of chemical additives demands precise measuring equipment for amount of substance. Installation of meters will allow increasing additives consumption efficiency when adding them to the solution. This option to be agreed with the client. Up

- video surveillance system. Upon client’s request a concrete-mixing plant may be equipped with video surveillance system, which will allow key personnel or a responsible person surveying the operation of separate areas of the plant and condition of its elements. Four video cameras are installed in the operation zone of critical components, the information is sent to a special device – a quad splitter, which forms four images on screen of a display. Consequently one can survey different facilities simultaneously. There are several surveillance modes: one facility, two facilities or each one by turns. By agreement video cameras may have infra-red lighting to enable functioning in low-light areas. This option to be agreed with the client. Up

 - distributed monitoring and control system. Upon client’s request a remote PC for a technologist may be installed, which will allow modifying formulas remotely. In addition dispatcher’s workplace may be equipped with a PC, which will enable order picking and binding a truck with a particular order. The information is displayed at operator’s screen. In such a scheme operator just surveys the concrete-mixing plant operation and fulfillment of orders, received from the dispatcher. Up

- installation of load cells to cement silos. Installation of load cells to cement silos allows direct controlling of incoming and consumed material. Up

- platform truck scale. Equipping a concrete-mixing plant area with platform truck scale having load capacity of 10 – 50 tons will ensure objective inventory control of incoming materials. Up

Components for high-precision batching system

Load cells up to 500 kg

Manufacturer

Country

Model

Price*, UAH

Applicability

HBM

Germany

Z6FD1

1750        

Installation

UTILCELL

Spain

350

1780        

Interchangeable

Flintec

Germany

SB14

2100       

Interchangeable

Тenzo-М

Russia

H4

2196       

Interchangeable

Zemic

China

BM 8D

1755       

Interchangeable

Keli

China

SQB-A

592    

Interchangeable

Vishay

Israel

SQB

850         

Interchangeable

CAS

Korea

BS

1320

Interchangeable

Load cells up to 2000 kg

Manufacturer

Country

Model

Price*, UAH

Applicability

HBM

Germany

RSCBC

2815       

Installation

UTILCELL

Spain

650

2370      

Interchangeable

Flintec

Germany

ULB2K

3670      

Interchangeable

Тензо-М

Russia

С2

2800       

Interchangeable

Zemic

China

B3G-C3

1755       

Interchangeable

Keli

China

Def-A

1035       

Interchangeable

Vishay

Israel

STC-2T

1590       

Interchangeable

CAS

Korea

SBA

1320    

Interchangeable

Weight indicators

Manufacturer

Country

Model

Price*, UAH

Applicability

HBM

Germany

WE2110

6107

Installation

Rimstrum

Austria

R420-K401

6800     

Analog

Flintec

Germany

FT

5120     

Analog

Keli

China

CI-5200A

3 623    

Analog

Vishay

Israel

VT400

4255     

Analog

Explanator notes to the tables

Components – frequency converter

Manufacturer

Country

Model

Price*, UAH

Applicability

SchneiderElectric

Germany

ATV31HD11N4

10500

Installation

Delta

Holland

VFD110B43A

7980

Analog

Omron

Japan

MX2

11400

Analog

Hyundai

Korea

N700

7455

Analog

Hitachi

Japan

MX2A4110-E

11626

Analog

Explanatory notes to the tables

       * - supplier’s price as of 01.10.2011

1. Installation – equipment used in our plants now.
2. Interchangeable – equipment may replace the one already installed
3. Analog – equipment functions are the same, as of the one installed, but it demands compatibility testing with the rest of equipment.

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