aking bread is a very precise process, requiring accurate control of the furnaces from start to finish – and this was a task
faced by Mechatronics (a system integrator and official distributor of Delta Motion, Drive, Control, and Robotics products) of Bulgaria. The bread furnace machine needed four
temperature zones, the first of which is especially powerful to compensate for the cooled conveyor belt and the relatively cool loaf entering the oven. Here, steam is also injected into the furnace to give it that freshly-baked sheen. This is then followed by three temperature-controllable baking zones that are carefully controlled for baking the optimal loaf. The conveyor belt must also be held at the correct speed throughout the process; and a human-machine interface (HMI) was needed to configure the baking process, deliver temperature status of each zone, and output any error status information.
To meet the demands, the team selected the Advanced HMI DOP-107WV from the DOP-100 Series. This touch-based control panel features a 16:9 7in colour TFT screen with a narrow frame, multilingual support, and user-friendly editing software to ensure that the final user interface was easy to navigate. With several RS-485 capable COM ports, it integrated perfectly with the other components selected for the furnace. According to the company, the
flat, wipeable, surface of the DOP-107WV proved the ideal choice for a dusty bakery. Control for the conveyor was implemented using an MS300 Series inverter. This AC motor variable frequency drive (VFD) also supported the RS-485 Modbus interface and is ideal for open-loop control of IM and PM motors. Special attention was also given to selecting
the optimal control approach for the seven heating elements of the furnace. After careful deliberation, the DTC1000 Temperature Controller was selected as the main controller, with DTC2000 controllers used in parallel for the remaining six heaters. These are also connected to the Modbus. The selection of established, reliable components, along with the careful programming, were critical in delivering a low-maintenance design that could be operated 24/7. To provide optimal temperature regulation,
the auto-tuning function of the DTC1000/2000 was used. The inputs are acquired from third- party PT100 temperature sensors while control of the heating elements is implemented with solid-state relays. Auto-tuning uses a training process to configure the closed-loop PID controller once the sensors and heaters are installed in this 250kW furnace. Further complicating the implementation is the dual heating and sensing of the last three baking zones. With one heater above the conveyor and the other below, each needs to be set to a different temperature. Spare outputs from the
Delta Temperature Controllers were available and linked to relays for audible and visible alarm signals. These signals were also replicated in the DOP-107WV HMI. Another important element is the speed
control of the conveyor belt. The MS300 VFD is linked to an inductive proximity sensor that is easy to clean and remains accurate in the dusty environment. Installed closed to the gears, the built-in programmable logic controller (PLC) of the MS300 is configured to monitor and calculate the conveyor speed. This is continuously compared to the setpoint defined in the HMI. As a result, the end- customer only needs to set the desired baking time, the required temperature, and then press run to start baking. According to Mechatronics, the wide range
of industrial automation solutions in the Delta portfolio were a huge benefit to this bread baking application. Victor Ogedegbe, field application engineer
at Delta, commented: “The bread furnace project has highlighted the skill required of both bakers and engineers to create a machine that delivers the perfect loaf. The auto-tuning function of the DTC1000/2000 played a large part in ensuring that bakers can deliver a quality product every batch, by providing excellent temperature control.”
Zytronic’s Iberian partner IBHM has been supplying Majorca-based
Hi-Services with Zytronic’s 43” touch sensor since 2018. The touch sensor provides the interactive interface for the HiPoint outdoor health awareness kiosks, which are installed near beaches. Due to the location in which they’re being used, Hi-Services needed a
product that could withstand high ambient temperatures, sand, saltwater and potential tampering. So, to meet demands, the company chose thick, thermally-tempered anti-glare glass ZyBrid touch sensors. A UV index indicator is featured on top of the kiosk to alert the
population using a code based on five colours (green, yellow, orange, red and violet), established by the World Health Organization (WHO) with UV index values ranging from 1 to 11. Additional kiosk features include an automated external defibrillator (AED) and emergency service call-out
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button; and there are also power outlets for charging mobile devices, electric wheelchairs, and mobility scooters.
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