Crushing and Screening Plant Automation

The control strategy covers how the plant equipment works together. Manual and automatic modes, start and stop sequences, and interlocks between equipment are defined in the PLC software. This strategy determines which equipment is affected by a fault signal from a unit.

• Crushers: monitoring motor current and defining operating interlocks with other equipment.
• Screens: controlling vibration motors and monitoring fault information.
• Conveyors: sequential starting and stopping according to the line operating sequence.
• Feeders: controlling feed according to crusher load.

We install and mount belt weighing systems at plants. We monitor the instantaneous material flow on the belt, record the total quantity conveyed and prepare reports.

We use belt weighing to dose material during truck loading.

The PLC controls the equipment; the HMI operator panel or SCADA screen lets the operator monitor the plant and issue defined commands. Screens can display equipment status, motor loads and alarms. The information displayed is selected according to the available measurements and field signals.

We treat the alarm screen as more than a warning list. Equipment names and fault descriptions are prepared alongside the control strategy so that operators can identify the unit with a problem. If multilingual screens are needed, the languages are agreed at the start of the project.

We record crusher and motor operating hours and notify the operator when maintenance is due. Maintenance alerts can therefore be tracked against equipment operating time.

Alongside new installations, we retrofit existing crushing plant automation. We identify the software, screens and panel components to be changed according to the condition of the existing system and your intended operation.

Automating a manually controlled plant and upgrading an operating PLC system involve different scopes of work. Before a retrofit, we assess the existing control arrangement, panel and field connections. We clarify whether the work requires screen changes, software modifications, or panel and wiring work.

• PLC program revision and software updates.
• HMI screen upgrades and plant display layout changes.
• Automation panel testing and any required rewiring.
• Assessment of program backup and restore requirements.

We provide remote plant monitoring, control and report access from a phone or computer over an internet connection. Instantaneous and total belt weighing quantities and plant reports can also be included in remote monitoring.

The accessible screens, reports and remote control operations are defined according to the plant infrastructure and project scope.

We plan software and panel work together with on-site commissioning and system testing. Start and stop sequences, operator commands and fault notifications are checked against the agreed plant operating strategy.

PLC/HMI program backups, electrical drawings, an operating manual and operator training are included in our standard handover.

When the customer provides internet access, we can connect for technical support through the customer's computer or our remote access devices. For modifications during production, the work schedule and planned plant shutdown should be shared before quotation.

In the first discussion, we need to understand the current condition of the plant and the changes you expect. An equipment list is the starting point for a new line; an existing plant also requires details of its control system.

• Plant location and whether it is mobile, stationary or tracked.
• A list of crushers, screens, conveyors and feeders.
• Existing PLC/HMI details, electrical drawings and panel photographs, if available.
• Your new installation, retrofit or technical support request, and any problems observed.
• Your intended schedule and any production shutdown that can be planned.

Does crusher automation mean the same service as crushing and screening plant automation?

Crusher automation refers to control of the crushers and the associated crushing and screening line. We define the scope from the list of screens, conveyors and feeders to be controlled alongside the crushers.

Can an existing plant be upgraded through software changes alone?

Whether software changes can meet the requirement depends on the condition of the existing PLC, screens, panel and field connections. During the initial assessment, we distinguish software revisions from work requiring hardware changes.

Does every plant need both HMI and SCADA?

The need for an operator panel and SCADA is assessed according to the equipment to be monitored and the required control arrangement. We can discuss the screen scope based on the information you need to see and the operations you want to manage.