Automated emptying process at the quarry - HTL Braunau
The idea for the project
How did the project come to be?
Loading up silo trucks in quarries has traditionally been a cumbersome and time-consuming process. First of all, the driver always has to climb up the silo to check the current fill level or simply take an educated guess. Then, in order to empty the silo, the driver must position it under the conveyor belt, get out of the truck and go into the next building. Once he is there, he has to use an outdated switchboard to select the desired silo and then press a button to open it. He also has to press buttons to activate each of the conveyor belts individually.. Since the conveyor belts don't distribute the load evenly, the truck must constantly be repositioned to utilize its full volume. For the driver, this means leaving the building to get back into the truck again. Once the loading process is complete, the driver must return to the control room yet again in order to turn off each component individually. Only then can he return to the vehicle to transport the material. With our project, we wanted to both simplify and modernize this tedious procedure.
What is special about your project? What makes it challenging or difficult?
Our idea was that the truck driver would have a tablet in the vehicle displaying the fill levels both in visual form and as a percentage. The emptying process would be activated with the touch of a button. The most difficult part of this project was finding a sensor that could deliver accurate measurements despite the extremely dusty atmosphere. In the end, we decided on an ultrasonic sensor with an output of 4-20 mA depending on the measured distance. The values are converted by the controller and displayed in the form of a bar graph. The controller itself is a 10" Power Panel that is mounted right onto the control cabinet. The tablet is connected to the controller using VNC Viewer. To improve safety, ripcords were also added to each conveyor belt and additional emergency stops to the building. All of this safety equipment is monitored by the controller, so if it is activated the process it can be partially or completely shut down.
What is your proposed solution and how do you plan to implement it?
- Our primary goal was to increase efficiency. Since the silo truck driver no longer has to guess what the fill level might be and can accurately plan when the silo needs to be emptied, he now has more time to finish other work or to direct his attention to maintaining the other equipment. This also eases the workload of the employee since this new procedure saves him long walks and trips up and down staircases in addition to allowing him to stay in the cab of his truck where it is not so dusty.
Which B&R hardware is being used?
- 1x Power Panel C70 10"
- 1x 24 VDC power supply 0 PS1100.1
- 1x X20 bus controller BC0083
- 11x X20 bus module BM11
- 11x X20 terminal block TB12
- 1x X20 power supply module PS9400
- 1x X20 power supply module PS2100
- 1x X20 bus base BB80
- 3x X20 analog input module AI4622
- 4x X20 digital input module DI9371/DI8371
- 4x X20 digital output module DO8322
Networking via POWERLINK
Topology drawing under resources