The requirements for the bread furnace machine defined four temperature zones. The conveyor belt of this traveling oven design must also be held at the correct speed throughout the process. Rounding off the specifications was a human-machine interface (HMI) to configure the baking process, deliver temperature status of each zone, and output any error status information.

The Mechatronics Ltd. team benefited from the broad range of industrial automation solutions in the Delta portfolio. Integration of the VFD, HMI, and Temperature Controller was simplified thanks to the out-of-the-box interoperability and connectivity of the components selected. For the HMI, the team selected the Advanced HMI DOP-107WV from the DOP-100 Series. This touch-based control panel features a 16:9 7” color TFT screen with a modern-looking, narrow frame. Its multilingual support. Considering the operating environment, the flat, wipeable surface of the DOP-107WV proved the ideal choice for a dusty bakery.

Special attention was given to selecting the optimal control approach for the seven heating elements used, the DTC1000 Temperature Controller was selected as the main controller, with DTC2000 controllers used in parallel for the remaining six heaters. To provide optimal temperature regulation, the auto-tuning function of the DTC1000/2000 was used. The inputs are acquired from third-party PT100 temperature sensors while control of the heating elements is implemented with solid-state relays. Auto-tuning uses a training process to configure the closed-loop PID controller once the sensors and heaters are installed in this 250 kW furnace. Closely coupled with the quality of the bake is the speed control of the conveyor belt. The MS300 VFD is linked to an inductive proximity sensor that is easy to clean and remains accurate in the dusty baking environment.

“Construction of the bread furnace was simplified by the availability of components that are interoperable and fulfilled the requirements demanded by our customers. Accurate temperature control was most critical for us, and the Delta team's support was essential in configuring the DTC1000/2000 auto-tuning function. This assistance contributed to the project moving from the initial design stage to full production.” said Toma Draganov, Automation engineer at Mechatronics Ltd.

Intelligent temperature control and human-machine interface help precise baking