Flexibility and versatility are two of the most prominent features of programmable controllers from the Nexto Xpress line. With a wide range of onboard resources, Altus' compact PLC delivers performance and high connectivity for controlling systems in the most different market segments. Recently, this versatility was applied to a solution that can be used both in concrete plants and in fertilizer industries.
Developed by Cybercontrol, the solution is used for the production of blocks and pre-cast , in the case of concrete plants, as well as fertilizers of the NPK type (nitrogen, phosphorus and potassium). Responsible for controlling the dosing, movement and mixing processes of raw materials, the solution controls the scales, humidity sensors, motor drives, conveyors, gates, cylinders and electro-pneumatic valves used in the system.
High connectivity and IoT capabilities with PLC Xpress
A aplicação desenvolvida utiliza como peça-chave o CLP XP340, modelo mais completo da linha Nexto Xpress, com um CLP XP300 atuando como expansão de E/S, aumentando a oferta de pontos de comunicação e permitindo que o CLP interaja com mais dispositivos. Na arquitetura aplicada, a expansão entre os CLPs é realizada via CANopen e a comunicação do XP340 com os dispositivos de campo é feita através da porta serial RS-485 e do protocolo MODBUS RTU. Em alguns casos, a solução também conta com uma IHM da Série X2 para inserção de receitas e controle de produção.
In addition to the equipment operating in the field, the solution also has a cloud platform for storing and processing data and a SCADA system for supervising the production process. To send operating data to the cloud platform, the Nexto Xpress PLC uses the MQTT communication protocol, while communication with the supervisory board is done via OPC DA. In turn, supervisory software can also do cloud database queries using the MQTT protocol.
The difference in the Altus experience
In addition to the usual fast and dynamic service from our pre- and post-sales teams, another difference that made Altus the technology supplier chosen for this project was the excellent connectivity and cost-benefit of the Xpress PLCs. Designed to meet the demands of highly connected environments, the solution has varied communication interfaces and support for different protocols, which allows it to interact with a wide range of devices. Family controllers can also communicate directly with the most relevant cloud hosting services on the market, such as Microsoft Azure, IBM Cloud, Google One and Amazon AWS.
The new architecture gave more precision to the raw material mixing process and speed in communicating between the PLC and field devices, increasing the agility in the management team's decision-making. The solution applied also helped to reduce operating costs, both in the concrete manufacturing process and in fertilizers.
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