Application requirements
I/O density, cycle time, motion or process requirements, field distances and maintenance needs are assessed together. This defines the requirements of the working system, not just individual products.
Samkoon · Machine automation
Integrated HMI and PLC control for drying equipment
This machine automation application uses HMI, PLC and field signals to address field control, reliable communication and maintainable commissioning.
Solution architecture
The proposed architecture combines HMI, PLC and field signals with the machine’s existing control infrastructure and communication protocols. Final product and module selection depends on site requirements.
How can ProControl help?
ProControl can adapt the solution to local project requirements in Türkiye, from site assessment, I/O planning and protocol selection to panel layout, commissioning and after-sales support.
Official application content
Technical details, tables and application images
The technical workflow and visual information from the manufacturer are presented below.
Project Background & Industrial Control Requirements
Continuous mesh belt drying machinery requires highly efficient thermal utilization and strict clean-air path segregation to prevent combustion contamination. The process involves routing raw material through an “S”-shaped multi-layer conveyor matrix while managing upward thermal air pressure. To optimize fuel costs using biomass particle combustion exchangers, the automation infrastructure must handle multi-node RS-485 Modbus telemetry, calculate real-time motor RPM speed conversions, and execute automatic threshold fan switching to eliminate uneven dehydration and minimize thermal waste on the factory floor.
Hardware Architecture & Configuration BOM
| Hardware Category | Implemented Model | Specific Role within the Architecture |
|---|---|---|
| Logic Control Layer | Samkoon FAT-16MT PLC | Primary controller executing Modbus polling loop and computing real-time mathematical estimation algorithms. |
| I/O Expansion Layer | Samkoon S-E8X8T Module | Expands localized discrete inputs/outputs for multi-stage fan relays and safety interlocks. |
| Operator Interface Layer | Samkoon SK-070QE HMI | Formulates the visualization terminal over a dedicated non-OS micro-kernel. Manages multi-point sensor registers, velocity tracking, and over-six-month telemetry logging. |
| Network & Inverter Layer | Modbus-RTU over RS-485 | Directly interfaces with variable frequency drives (VFD) via digital serial commands to regulate conveyor motor speed dynamically. |
Core Control Logic & Mathematical Implementations
- Multi-Point Environmental Telemetry: The architecture continuously logs 9 discrete temperature tracking registers and 8 standalone humidity detection probes . The PLC logic handles layered spatial mapping to pinpoint regional clogs or airflow cold spots instantly.
- Digital Mesh Belt Speed Calculation: Instead of error-prone manual tracking, conveyor running speed is calculated mathematically within the PLC execution loop using motor speed registers and known physical constants.
- Real-Time Kinematic & Production Estimation: The system utilizes mathematical models to project exact batch discharge times and real-time throughput metrics per minute based on the stacking density matrix.
Embedded Kinematic Formulas
1. Mesh Belt Running Speed (m/min):
Mesh Belt Speed = (Motor Speed / Deceleration Ratio) × 558.8 mm
2. Discharge Time Estimation (min):
Discharge Time = Total Mesh Belt Length / Mesh Belt Running Speed
3. Material Output Estimation (kg/min):
Output = (Equipment Area × Material Thickness × Stacking Density) / Discharge Time
Functional Telemetry & Software Boundaries
- Closed-Loop Thermal Regulation: Automatic start/stop triggers engage the heat source blower based on engineering temperature thresholds, preventing material scorching.
- Data-Logged Customer Management: The non-OS HMI local storage maintains over six months of isolated lot classification logs, recording stacking thickness, speed ratios, and batch runtimes securely.
- Power System Diagnostics: Integrates native bus monitoring to display live voltage and current readings, triggering safety lockouts before phase abnormalities cause motor winding failure.
Field Telemetry & Screen Interface Compilation
This content is based on the manufacturer’s published Integrated HMI and PLC control for drying equipment application, adapted by ProControl while preserving its technical scope. View the official manufacturer source.