Controls

In the following sections, the main components of our visualization interface will be illustrated using the images. We will use excerpts from breweries that have already been realized. As the interface can be modified, the quantity structures (display values, brew entries etc.) shown below do not represent maximum values.

The various process images are only intended to give the interested reader an initial insight into the operating philosophy of our brewhouse software. The actual structure is determined by the number of technological sub-processes and vessel of each individual order.

We see ourselves as your partner and work with you to develop the solutions you need to optimize your existing systems.

All components required for power distribution, the power units for pumps and other drives, power supply units, transformers, the safety-relevant assemblies and the programmable logic controller (PLC) are located within a central system control cabinet. As is usual in modern system structures, the valves are located in the form of valve terminals and the PLC modules for recording measured values are located directly in the system in small switch boxes. In order to minimize the cabling effort, these system components are connected to the main control system via industrial data lines, the so-called bus systems. Profibus or Profinet are used for this purpose in our systems.

Based on the system structure, the operation of the system is divided into several individual process screens. Each process screen contains the elements required for at least one tank, such as valves and drives, as well as the measuring points and default values for control processes. This makes it possible to obtain an overview of the current brewing process with just a few operating actions.

When operating the system, no fundamental distinction is made between manual and automatic processes. All elements not used by a running process can be controlled manually; switching by the operator is not necessary. The elements used include both the components to be controlled within the process and those that must be blocked for operation, for example, in order to prevent incorrect actions in the form of incorrect path openings.

Within the individual process screens, the operator has the option of changing certain parameters, interrupting the current sub-process or resuming automatic operation. Control panels for confirmations (iodine test, etc.) are also provided depending on the sub-process. The following figure shows an example of this for mash tanks.

In addition to displaying the system structure and the measuring points, it is also possible to operate the individual elements. In manual mode, the status of the individual actuators can be switched by clicking the mouse. Set values are entered by clicking on the input field and then entering the new value via the keyboard.

Complete integration of recipe input into the visualization system eliminates the need for licensing and maintenance costs for additional software. This system makes it possible to make changes during operation and test them immediately, as well as to create and maintain them at a later date. A simple, intuitive structure based on spreadsheets makes it very easy to learn.

All process-relevant elements (valves, motors, etc.) can be selected and conditions, set values (temperatures, pressure) and times can be specified.

It is of course possible to switch the language depending on the installation location.

Standard functions and optional accessory programs for WinCC are used for archiving and detailed error display.

Zur Archivierung und detaillierten Fehleranzeige werden Standardfunktionen und optionale Zubehörprogramme zu WinCC verwendet.

The “Brew data” screen is of central importance for the organizational process in the brewhouse. This is where the individual brews are defined in the desired sequence within the schedule. In addition to the time sequence, other brew-related parameters can also be entered at the customer’s request and adopted at the start. The number of possible table positions is not limited to the 30 shown here. At least the first entry in the table must have a time entry. If the start time is not specified, but the other data is plausible, the brew entered is automatically started when the first vessel is available. This enables the continuous realization of brews. In the type overview, the currently available beer types in the control system can be checked (this corresponds to the beer type specification in the schedule).

Below the flow chart, the current vessel occupancy by the individual brews and their current brew numbers with the corresponding beer types are displayed.

An essential part of the modern brewing process is keeping records of the brews that have taken place. In order to give the brewmaster a wide scope for designing the brew log, the desired entries for the brew log are already defined within the recipe. This allows the brewmaster to determine the time and content of the entry. Using the “Create document” control panel, the brew log is saved as a file on the PC and can be archived.

For further brew-related archiving of curves and input values, the “PM Quality” option package can be used on request, which requires a license and is not included in the standard scope of delivery.

System malfunctions are not one of the most pleasant moments in the life of a brewmaster. Therefore, a clear statement about the problem that has occurred is absolutely essential for rapid troubleshooting. For this purpose, any erros that occur are entered directly in a message line on the system screen. In the special “Error messages” screen, the “current” pending errors and the last errors that occurred can be checked again. In addition to technological errors, such as timeouts, the monitoring options are determined by the system equipment with sensors and transducers.