Remote-controlled elevators

To automate or not to automate - that is the question

If you have ever faced the task of building a new or reconstructing an existing grain elevator, the question of equipping it with an automatic control system has probably been raised. The reason for this is that today it is impossible to imagine effective control of a modern, highly productive complex in manual mode.

High productivity and power of transport mechanisms, large capacity and number of tank equipment, variety of types of grain crops simultaneously processed at the elevator requires from the operator lightning-fast decision making, optimal choice of grain transportation routes.

Some of the first control systems were huge power-consuming cabinets, with starting equipment, allowing remote control of equipment, without the functions of elementary control of their work.

As storage volumes increased, these systems were supplemented by relay cabinets, whose task was to control an increasing number of mechanisms in an interlocked manner so that the complex could be controlled in some way. These relay cabinets had a low degree of reliability (contact elements), consumed large amounts of energy, and required the constant presence of a small number of maintenance personnel.

The era of microelectronics came, which completely changed the perception of the possibilities of control systems. At first it seemed to be very expensive and not a quick payback. But every year the cost of automation equipment is decreasing, reliability has grown to high levels, and grain storage and elevator management systems have come to include this technology.

Automation or surrogate

The modern market of services does not suffer from the absence of various proposals for the automation of elevator complexes. But this does not give any guarantee that professionals will appear in front of you.

When you turn to a company that develops automated grain elevator management systems, you have to put all your trust in their experts. In doing so, you must clearly understand that the success of your entire business depends on their experience and knowledge of the grain handling industry.

In practice, it is very often the case that some development companies under the auspices of automation offer a set of some list of works, including replacement of cabinets of electrical power equipment, installation of control cabinet, maybe even on the basis of programmable controllers, carrying out a sequential start of mechanisms and a beautiful picture on the monitor of a personal computer, which supposedly displays the process. As a rule, the main criterion of such proposals is a low price.

Such a price is formed due to the fact that such an offer implies the installation of electrical equipment of little-known manufacturers, with questionable reputation and reliability, and the customer will be convinced that there is no point in overpaying for a "brand". As means of control will be laid in the project controllers, which are designed to solve small problems and by their power is simply not able to realize the algorithms necessary for the technological process. But even here the main criterion will be their relatively low price.

What is important to know during automation

It is always necessary to remember: in order to ensure reliable, high-performance, high-efficiency, energy-saving, safe operation of the elevator complex equipment, which, by the way, is quite high in cost, starting protection equipment must comply with IEC 695-2-2 standards for class no less than V2 in accordance with UL94 (resistance to ignition), MTBF, vibration resistance and dust resistance.

As for controller technology, it should be understood that there are several classes of programmable controllers. The conditional lineup of these devices is approximately as follows:

• Programmable relays.
  
• Logic modules for solving local tasks, replacing small relay circuits.
• Microcontrollers for building control systems for small machines, dispensers, filling or packaging machines.
• Universal programmable controllers for building control systems for small flow or conveyor lines.
• High-class controllers designed to realize tasks with complex algorithms, supporting a large number of input-output channels, with speed sufficient for the time of the technological process.

To realize the tasks that are required for modern elevator or grain storage complexes, you need a level of equipment that corresponds to universal programmable controllers or high-end controllers. And these are the controllers that belong to the high price niche.

Of great importance is how well thought-out the elevator control algorithms are, how well they are adapted to real life, how ergonomic and consistent the interface between the operator and the automated workplace is.

Grain Capital elevator automation

The specialists of our Grain Capital group of companies have gone beyond the standard turnkey approach to elevator automation. We realize that in today's marketplace, our customers are no longer satisfied with simple solutions!

We are proud to introduce a new standard in the industry -"Remote Control Elevators".

We offer our customers solutions that are fully compliant with European standards and the modern requirements of the grain storage industry. Our grain elevator automation covers a range of complex tasks including:

• Full control and monitoring of grain transfer routes within the elevator: The system allows real-time tracking of grain movement, ensuring safe and efficient grain handling.
  
• Receiving and shipping by various modes of transportation: Includes road, rail, sea and river transportation, providing flexibility and speed in grain handling.
• Control of conveyors, gates, flip valves and distributors: Automatic control of the various elements of the system ensures continuous grain handling and storage.
• Management of associated aspiration systems: Includes control of air purification systems, critical to maintaining a clean and safe production environment.
  
• Operational data collection and processing of equipment status: Our system continuously monitors and analyzes the status of all equipment, providing early detection and warning of potential malfunctions.
• Diagnosis of accidents and deviations from process parameters: The system detects and signals accidents and deviations, providing information on the nature of the fault and recommendations for corrective action.
• Preventive actions to avoid equipment blockages and route stoppages: Automation includes features that prevent potential stoppages and blockages, ensuring uninterrupted processes.
• Motor load current monitoring and spill rate control: Ensures maximum productivity and efficiency of transport equipment and prevents emergencies.
  
• Hopper and silo availability monitoring: Automatically monitors grain levels in storage tanks to prevent overfilling and shortages.
• Prevent grain mixing: Control technologies ensure grain purity and quality by preventing grain mixing.
• Display of process parameters in various graphical forms: Data visualization helps to easily monitor and analyze system performance.
• Keeping production protocols: Collect and store data on the complex operation for further analysis and optimization of processes.

Our advantages

• The entire electrical switching complex, which we offer, is located in cabinets of the new design Spacial SF manufactured by Schneider Electric (France). These cabinets are made of 1.5 mm thick steel, coated with polymer powder coating with pre-phosphatization, and certified according to the international standard ISO 9001:2000 PRA with the degree of protection IP55.
• Control and electrical distribution circuits are created on the basis of components of leading European manufacturers, such as "Siemens" and "Eaton" (Moeller, Germany), with the use of bus connection technologies, which ensures optimal placement and safety during system maintenance.
• To collect data from remote equipment, distributed water output devices from "Siemens" or "Phoenix Contact" (Germany) are used. Justified use of wireless devices "Phoenix Contact" and "Weidmuller" allows reducing the cost of cable and wiring products up to 30%.
• Automation systems are powered by uninterruptible power supply devices, which protects controller equipment from voltage fluctuations and saves data on the status of process equipment during power restoration.
• Communication between automation devices is carried out using fiber-optic communication protocol ProfiNet, which provides high speed and reliability of data transfer.
• The upper control level is based on the server-client structure with the possibility of working in the hot standby mode, which increases the system reliability.
• The architecture of our system is designed in such a way that the failure of individual technical means does not lead to the loss of control functions of the entire complex. The modular construction principle, the available editing mode and the use of open industrial protocols OPC and ProfiNet make it easy to modernize the system and add new elements, gradually expanding production.
  
• The software we have developed enables fast and cost-effective realization of automation systems. Carefully coordinated system components allow for efficient horizontal and vertical integration - from field installations to control systems, visualization and information technology. All components are easy to use and support standardized interfaces.

One of the most important features of our automation systems is the comprehensive delivery. Together with the equipment and steelwork, you get all the necessary components, from control cabinets to cable products and even terminals, which allows for high-quality, fast and cost-effective electrical installation.

This is our new era of "elevators to remote" services. When you work with us, you'll see how quickly your new or remodeled elevator complex will start to turn a profit.