Several key elements can be distinguished in the architecture of the analytical system created by BRAINHINT: PLC controller, IPC, SCADA system and graphic interfaces providing the output data for the supervisor and the operator.
Sensors from the production line collect, among others, information on temperature and humidity. This data goes to the SCADA system, which aggregates and monitors production information. The aggregated data is then sent to the analytical system running on the Linux server. The output data is transferred to the operator’s device via the graphic interface, combined with audio-visual notifications. Prediction data can also be displayed directly within the SCADA system. In turn, the supervisor’s system is provided with historical data, information on the system sensitivity configuration and model parameterization.
The key information obtained through this architecture covers e-mail notifications about anomalies. Each time the model results indicate an unusual event somewhere across the production line, an alarm is triggered and a relevant notification is sent to the operator’s inbox. Ultimately, notifications about failures will also be displayed through the dryer operators’ dashboards. Comprehensive reports summarising the production data following each alarm are also delivered 15 minutes after the anomaly occurs. These contain graphs of humidity, temperature and ingredients dosing process, covering the period of 15 minutes before and after the alarm. They help the operator discern better whether the alarm generated was valid.
Other important functions of the system include the possibility of cross-checking the batch quality. There is a summary of events generated when the batch that triggers the alarm leaves the dryer, and the chart shows the conditions under which that given portion of pasta has been dried. Any occurrence of unusual behaviour is marked in yellow.
Thanks to the data supplied by the system, it will also be possible to analyse the conditions in which a specific portion of pasta is dried. For easy navigation and to follow the full course of the production conditions, the operator can scroll the screen with a slider. The analytical data is also used to control the quality of final products more efficiently. Further work on this system will enable the development of this already proven solution to be implemented across a wider industrial setting.