Not so long ago every bakery out there was dependant on the paper stored recipes and manual weighting. Not only such process took more time than it should but also was quite prone to human error. That's why more and more bakeries nowadays are being improved with automation solutions.
Here, we are going to look at the bakery application with multiple OCS units installed. The central QX unit is responsible for handling recipes (about 200), overview of the process and communication with the compact XLe units. The QX size of 10 or 12" should be enough to give the user a SCADA like experience and precisely monitor every aspect of the process. Communication between the two is handled over peer-to-peer CsCAN network which gives the benefit of fast and easily accessed information.
QX - Overview OCS
Ethernet port on the main QX OCS gives a remote access not only for the user's benefit, but also for the system integrator, who can support his application over distance and in a much faster way. Such support includes of course debugging and re-programming (if needed) over Cscape, but also (together with Envision RV) remote access to all diagrams and data fields displayed on any of the QX screens. As for the recipes, Envision FX guarantees easy Import and Export over Ethernet without any interference with the process. Any recipe update is handled seamlessly and can be done manually or in a scripted manner.
XLe - Protocol Handler Units
Once the proper recipe has been loaded, all necessary information are being transferred over CsCAN network to the multiple XLe devices. They are responsible for the proper dosage of water, flour and other ingredients as well as for the water temperature. All this is achieved by using a remote SmartStix I/O (also on the same CsCAN network) and both XLe communication ports. One of them is connected with a weight controller over Modbus RTU, the other is exchanging parameters with the water system via custom RS232 protocol. Both communication ports are working independently, all together with the CsCAN messages being exchanged between the central QX unit.
Cscape Program Example
The zipped package consist of two Cscape files (for QX and XLe) including:
- Hardware configuration (QX551 + XLe + SmartStix Digital I/O)
- CsCAN data exchange code for both units
- QX and XLe Overview screens
- Recipe handler for QX (menu Program -> Recipes Editor)
- Sample protocol configuration for XLe (menu Program -> Protocol configuration)
(Cscape 9.10B or higher needed)
Advantages of this automation solution are obvious. No more paper recipes or manual weighting, all ingredients dosed precisely and automatically. Such approach gives the benefit of the high quality products every single time, while significantly lowering production time. Powerful recipe handler, simple communication between the stations and optional datalogging - all this and more makes the Horner products very successful in this type of applications.