Automated grain silos
- Country PL, Gruszów
- Build year 2023
- LOXONE partner ARTUR MRUKOT
Challenge
The project involved the automation of loading processes, filling control and failure diagnosis.
Solution
The system controls the condition of the heap piled up on the screw feeder, which feeds the dryer. Once the drying process is complete, the material is automatically transferred to the buffer silo and further material from the heap is drawn into the dryer.
The buffer silo is monitored for filling and ventilated automatically by a blower. Once full, a sensor gives a signal for the contents to be transported along one of two transport lines.
The feeder and conveyor motors are started in order from the end, one at a time, in order to remove any residue when stopping. The order is reversed so that the material is completely delivered to the silo emptying the lines. Sequential starting also aims to reduce the starting current of the entire line. Automation allows remote selection of the target silo by opening a selected gate.
The silos are monitored by capacitive sensors for their filling status.
The system will be extended to include temperature and humidity sensors, which will report if the standard is exceeded and give information to the aeration fans to trigger the aeration mode.
The system monitors the operation of all motors, dryers and the condition of the grain material in the silos. It also monitors the status of phase symmetry protection, voltage and current, causing the entire line and dryer to shut down. It triggers an alarm and sends a notification to the telephone in the event of failure of one of the components. The big advantage of such a solution lies in the correct and immediate diagnosis and location of the breakdown.
The customer additionally has the option of activating the service mode and manually starting each engine via an app on his phone, which is very important for the customer during maintenance. Being at altitude, he is able to test and check the work of individual components himself.
The system was commissioned last year and worked continuously for four months after commissioning. There were no failures of any kind and maintenance was greatly accelerated and facilitated.
The customer is fully satisfied and plans to expand the system with the temperature and humidity sensors mentioned. He also wants to integrate all the other motors, feeders, fans and silo gates that are not yet part of the system.
The plan is also to build a 50 kW photovoltaic installation with 40 kWh energy storage to provide energy for the entire system. The installation is to be linked to the Loxone system to manage the energy to use temporary surplus PV production, for example to reduce moisture in the silos where it is highest.
The buffer silo is monitored for filling and ventilated automatically by a blower. Once full, a sensor gives a signal for the contents to be transported along one of two transport lines.
The feeder and conveyor motors are started in order from the end, one at a time, in order to remove any residue when stopping. The order is reversed so that the material is completely delivered to the silo emptying the lines. Sequential starting also aims to reduce the starting current of the entire line. Automation allows remote selection of the target silo by opening a selected gate.
The silos are monitored by capacitive sensors for their filling status.
The system will be extended to include temperature and humidity sensors, which will report if the standard is exceeded and give information to the aeration fans to trigger the aeration mode.
The system monitors the operation of all motors, dryers and the condition of the grain material in the silos. It also monitors the status of phase symmetry protection, voltage and current, causing the entire line and dryer to shut down. It triggers an alarm and sends a notification to the telephone in the event of failure of one of the components. The big advantage of such a solution lies in the correct and immediate diagnosis and location of the breakdown.
The customer additionally has the option of activating the service mode and manually starting each engine via an app on his phone, which is very important for the customer during maintenance. Being at altitude, he is able to test and check the work of individual components himself.
The system was commissioned last year and worked continuously for four months after commissioning. There were no failures of any kind and maintenance was greatly accelerated and facilitated.
The customer is fully satisfied and plans to expand the system with the temperature and humidity sensors mentioned. He also wants to integrate all the other motors, feeders, fans and silo gates that are not yet part of the system.
The plan is also to build a 50 kW photovoltaic installation with 40 kWh energy storage to provide energy for the entire system. The installation is to be linked to the Loxone system to manage the energy to use temporary surplus PV production, for example to reduce moisture in the silos where it is highest.
I chose Loxone due to its operational stability, remote service, technical support and established position on the market
Artur, INSTALLER