MALT PRODUCTION LINE AUTOMATION

Malt production line. Malt turning machine is the main element of the malt production line. This is where actuators are located, such as the main driving engine, 9 drives that control screw conveyors, etc., together with sensors that monitor the performance of the turning machine. The main purpose of the malt turning machine is to germinate malt and feed it into a hopper. A SIEMENS-made S7-300 controller is used as a programmable logic device. It controls the technology of malt production and supervises the operating modes of the malt turning machine. A frequency converter is used as an actuator that controls the movement of the malt turning machine and adjust its speed.

PROCESSES AUTOMATION STRUCTURE

The automation system includes:

  • Malt turning machine equipped with the main driving engine and 9 drives that control screw conveyors;
  • Control cabinet that supervises the malt turning machine. It contains SIEMENS-made PLSs, frequency converter, automatic breakers, starting switches for 9 engines that turn the screw conveyors;
  • Sensors produced by SIEMENS
Решения для пищевой промышленности

 

Malt turning machine runs under two operating modes: manual and automatic.

  1. Manual operating mode. Under this mode, operator can make the malt turning machine move forward and backward and set all 9 screw conveyors in motion. Manual operating mode involves no automation, except for the sensors that detect the final position of the machine. If the discharge wrench is turned, the final position of the turning machine is the position opposite the discharge hopper. Otherwise, it is the end position of the machine while turning.

2. Automatic operating mode

This is the main operating mode of the malt turning machine, and it has several variations:

  • Turning mode
  • Discharge mode
  • Cleaning mode

A switch on the control cabinet switches between manual and automatic control modes.

Turning mode

Under this mode the malt turning machine moves steadily from one end position (G1SW01 sensor) to the other (G1SW02). When the malt turning machine approaches speed slowing sensor (G1SW11) at the beginning of the germination bed, it slows down and stops when it reaches the final position sensor G1SW01. The automatic control system reverts the direction of the turning machine.

When the malt turning machine reaches the speed slowing sensor (G1SW11) at the end of the germination bed, it stops immediately, and  the direction of the turning machine is reverted again.

When the malt turning machine is not moving (“Stop” visible signal is on), a human operator can change the direction of the machine by activating contact switches: G1SW01 — to make the machine move backward or G1SW02 — to make the machine move forward.

In case of emergency or if a human operator pushes “Emergency stop” button, the malt turning machine stops and the corresponding visible signal lights up. The turning machine also stops if “Stop” button is pressed or if “Ready to start” signal fails to be transmitted. In either case, the direction of the turning machine is not reverted after pressing “Start” button.

Discharge mode

The discharge mode is activated when the following conditions are met:

  • Three-position switch on the front panel of the control cabinet is turned to “Discharge” operating mode;
  • Automatic control mode is switched on;
  • Sensors show that the back wall is removed;
  • The wrench that allows discharge is turned to the right direction, which gives a signal to the PLC that the front wall of the turning machine is 
  • removed;
  • The visible signal of the alarm system is not on;
  • The malt turning machine is located in the zero position (final position of malt turning).

Cleaning mode

The cleaning mode is activated when the following conditions are met:

  • Three-position switch on the front panel of the control cabinet is turned to “Cleaning” operating mode;
  • Automatic control mode is switched on.
  • Sensors show that the back wall is in its place;
  • The wrench that allows discharge is turned to the right direction, which gives a signal to the PLC that the front wall of the turning machine is removed;

The visual signal of the alarm system is not on.

Implementation experience:

Object
Name of workWork
Year
Slavuta Malt Plant, PJSC Khmelnytsky region, Ukraine
Malting department. Turner and upload side of malting boxes. ACS TP modernization. Projecting, application software design, equipment supply, installation and commissioning
Slavuta Malt Plant, PJSC Khmelnytsky region, Ukraine
Malting department. Malting boxes’ ventilators. Electric motor ACS TP modernization. Projecting, electric installation and commissioning
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