Processing plants with multiple geographically separated production locations often face the challenge of centrally capturing and monitoring the levels of numerous process containers. An immediate and precise representation of these levels is essential to ensure smooth operations, efficient production planning, and control.
Precise Measurement Technology and Optimal Level Visualisation:
The Ideal System Solution for Connected Silo Batteries
In various industries, particularly in bulk material handling, the need for continuous level measurement combined with automated data visualisation is increasing. UWT silo sensors deliver measurement results quickly and easily using license-free software, providing convenient access directly from a screen. This effective logistics approach significantly enhances transparency and planning reliability for plant operators. Upon request, customers or suppliers of the processing company can also be integrated into the system. Combining level and point level measurements can lead to highly efficient solutions for bulk material management.
Challenge: Centralised Level Monitoring
for Multi-location Silo Batteries
In this application case, an international plastics processor faced the primary difficulty of mapping the exact levels of silo batteries across several production sites in real-time and making this information centrally accessible. Additionally, the sensors needed to operate reliably and precisely, regardless of the varying properties of the stored plastic granules, such as dielectric constant, dust generation, or fluctuating temperatures.
Everything in View!
Centralised Level Monitoring
in a Convenient Modbus Network
UWT implemented the project with a tailored solution through a combined installation of the NivoTec® 3500 for, the electromechanical plumb line system NivoBob® 3100 for level measurement, and the full detector .
The NB 3500 with Modbus RTU interface continuously measures the levels of various plastics in silos, regardless of bulk weight and dielectric constant. The Rotonivo® RN 3002 overfill alarm detector reliably supports the system, preventing overfilling. The paddle switch length and switching point of the Rotonivo® can be flexibly adjusted to suit the application. Both sensors are versatile solutions in the plastics industry, suitable for use with solids, granules, and powders, offering cost-effectiveness and ease of installation.
Optimal Monitoring and Control of Levels
The is a level visualisation system for displaying and monitoring levels and limits, ideal for complex applications. This standalone system operates with visualisation software on a web server module and can monitor up to 50 silos — or more upon request.
The NT 3500’s core is a web server module equipped with robust visualisation software. All level monitoring and display functions can be conveniently operated via PC or an illuminated foil touch panel. Its Ethernet interface enables simultaneous operation from all connected PCs with password-protected access. The control cabinet can be equipped with various operation and display elements, including a touch panel (10.4" or 15") or a digital level indicator with LED lights for full and empty notifications.
can be activated via the visualisation software or manually with a button. To provide an alert during an overfill event, an alarm horn can be installed on silos. A pinch valve control to stop filling in case of overfilling is also available. The NT 3500 offers a comprehensive solution, including power supply for the sensors, and comes with project-specific electrical planning.
The centralised monitoring of the levels in multiple silo batteries across various locations presents specific demands on communication and measurement systems:
Real-Time Data Availability: Efficient production planning requires real-time level data availability. UWT's Modbus network ensures that measurement data is transmitted immediately and without delay.
Precision and Reliability: The NivoBob® 3100 systems deliver precise measurement data, independent of varying material properties. This reliability is crucial for obtaining consistent and actionable information.
Centralised Management: With the NivoTec® NT 3500, the levels at all locations can be centrally managed and monitored. This enables management to respond quickly to changes and make informed decisions.
UWT's solution provides numerous advantages:
Increased Efficiency: Centralised collection and real-time visualisation of level data allow for better production planning and optimal resource utilisation.
Cost Savings: Accurate level measurement and the prevention of overfilling reduce material waste and production downtime.
Enhanced Operational Safety: The use of reliable sensors and a robust communication network minimises the risk of measurement errors and technical failures.
By implementing gateways and VPN tunnels to connect the three silo installations to the NT 3500 controller, the plastics processor significantly improved its operations, increased efficiency, and ensured operational safety. The flexibility and reliability of the technologies used have proven to be highly effective in the challenging environment of plastics processing.
Kernkomponenten der Systemlösung:
NivoTec® NT 3500: Dieses System bietet eine umfassende Visualisierung der Füllstände und ermöglicht die zentrale Überwachung. Es zeigt die Füllstände in Echtzeit an und stellt sicher, dass die Daten von allen Produktionsstandorten zentral abgerufen und analysiert werden können. Die drei Siloanlagen wurden über Gateways und VPN-Tunnel mit dem NT 3500 Controller verbunden, was eine sichere und zuverlässige Datenübertragung gewährleistet.
NivoBob® 3100: Die Füllstandmessung wird durch das robuste NivoBob® 3100 Lotsystem durchgeführt, das unabhängig von den Materialeigenschaften der Kunststoffgranulate präzise Messergebnisse liefert. Diese Unabhängigkeit von Variablen wie DK-Wert, Staubentwicklung oder Temperaturänderungen ist entscheidend für die Zuverlässigkeit der Messungen.
Modbus Netz: Die Kommunikation zwischen den Füllstandsensoren und der zentralen Visualisierung erfolgt über ein Modbus Netzwerk. Dieses Protokoll ermöglicht eine schnelle und zuverlässige Datenübertragung, wodurch die zentralen Systeme stets aktuelle und genaue Füllstandinformationen erhalten.
Rotonivo® - RN 3002: Zur Vermeidung von Siloüberfüllungen wird der Vollmelder der Baureihe RN 3002 eingesetzt. Dieser Sensor überwacht kontinuierlich den maximalen Füllstand und alarmiert rechtzeitig, um Überläufe zu verhindern.
