Production Control System

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DCS automation control system is composed of Siemens PLC hardware, that is decentralized control and centralized management mode, low failure rate and easy for maintenance.

All devices with the decentralized control system are equipped with on-site local control system, which can independently operate and monitor the machine in real time. Even one fails (manual intervention operation), the others can run normally. Compared with other brands (one point failure will cause the whole system stop), our system can quickly solve problems, resume normal production, and avoid heavy losses caused by waste cakes.

Centralized management mainly realizes through the combination of industrial Internet, field bus and AMES system information sharing. The system provides real and accurate historical data recording and intelligent management of device operation, fault diagnosis and remote operation and maintenance. Compared with other brands, we took the lead in developing remote intelligent operation and maintenance system for ALC production, providing timely and effective production information and remote service to all the customers.

• The whole system can start online operation, both parallel running and single running by one button control. Combining automatic and manual control methods, operators can switch freely from manual mode to automatic mode.
• High-power pumps adopt soft lifting mode, with both energy saving and voltage reducing.
• Data analysis for each motor records, system will alarm if any unexpected values.
• Count the working hours of each motor to provide data records on device life cycle management.
• Record and count the energy consumption of each motor to provide data for energy consumption management.
• The silo adopts high frequency radar + ultra-high tuning fork material level detection system, for continuous and point material level detection with double signal safety protection.
• The slurry tank adopts laser, ultrasonic, radar and other continuous material level detection. According to the material level, the motor current is calculated and compared with the actual motor current for analysis. Abnormal real-time alarm is provided for the underlying data pre-maintenance.

• The automatic measurement for slurry density + raw materials temperature + raw materials testing data + mould volume to automatically calculate the caloric value of the formula, to achieve automatic formula, multi-formula switching selection, to reduce the labor intensity of the processing, to effectively avoid artificial formula errors what caused by unqualified products.
• To control varieties of different materials at the same time for accurate ratio batching and dynamic adjustment.
• Instantaneous flow and accumulative quantity algorithm for coarse and fine metering control, to ensure the accuracy of batching.
• To detect screw conveyor in both blocking and temperature modes, to improve its safety and reliability.
• Real-time display of dynamic production processing, intuitive operation, with manual/automatic control mode.
• Complete report function, to record and store formula data and production data, for further querying and exporting.
• Perfect fault chain function and intelligent prediction, to avoid bad ratio, and realize alarm prompt function.

• Hardware redundancy of safety, collision-proof and in-place signals is set at the front and rear end of each section to ensure continuous and safe operation;
• P+F background control switch is suited to signals reception of different colors on target surface.
• Mis-transmission or interference signal in the software special editing processing, software redundant editing;
• Intelligent mesh cart dislocation of automatic cycle positioning, to solve the overload of fast moving equipment with different inertia of the parking impact, to correct resistance change indeterminacies which caused by mechanical structure.

• Hardware redundancy design, fault tree analysis, error proof signal software special editing processing, intelligent cutting cart automatic cycle positioning. The system has taken a serious of safety measures, such as manual/automatic switch, multi-level control, alarm and output lock, to ensure a high reliability and high security system.
• Adopt flexible control and operation precision to keep a good quality of products, saving raw materials and energy, reducing costs. The cutting process is a variable system with complex process, much random interference, high hysteresis, multi – input and multi - output coupling. Advanced control algorithm has been adopted to meet its variability, and reflects the practicality of the system.

• Based on the production process requirements and steam distribution process parameters, automatic conversion of steam curing process curve data can be made by the system.
• The instantaneous flow rate of exhausted steam can be controlled by automatically adjusting the valve opening in a precise manner.
• Detect the temperature on the autoclave surface and the pressure in the autoclave; the water content is calculated according to the set value of temperature difference and pressure, which automatically controls the valve for drainage and sewage.
• The reliability and safety of steam distribution is enhanced while ensuring high quality of AAC panels and blocks.

• All devices run independently and automatically, the associated devices through high-speed network and proFINET reliable protocol connect closed, with a high degree of continuity and reliability.
• If one of the upper computer fails, the neighbor computer will start with urgent control mode, it is safety and reliable.
• Data analysis for each motor records, system will alarm if any unexpected values.
• Statistical the working hours of all motors to provide data records on device life cycle management.