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
