System Integration & Control Systems Design


PC-based control for seed treatment

April 2022 System Integration & Control Systems Design

Founded in 1986 and headquartered in Não-Me-Toque in the Brazilian state of Rio Grande do Sul, Grazmec consistently depends on new technologies for its seed treatment machines. The latest developments from the machine builder have relied on PC-based control technology from Beckhoff as an important innovation factor. In particular, it has helped to open up the Internet-of-Things (IoT) for use in the food industry.

Seed treatment is a preventive way to protect against damage at the most critical harvesting stage. The application of chemical pesticides (fungicides and insecticides), micronutrients (such as polymers and pigments) and the inoculant against infectious materials in the seed, can be carried out in two ways: by on-farm seed treatment, i.e., carried out in the field just before sowing; or by industrial seed treatment (IST), i.e., carried out by the seed industry.

According to Grazmec, the latter option is more reliable, less strenuous and reduces environmental impact. As such, it is already the preferred choice of numerous seed companies, cooperatives and large farming operations.

Modern control technology revitalises machine design

Grazmec has been working with Beckhoff since 2019 to launch a completely redesigned seed treatment machine, as Grazmec’s marketing manager, Émerson de Mattos, explains. “The redesigned GV500i Connect offers improvements to both functionality and the available options, with Beckhoff technology facilitating an entirely new machine concept in the process. Having won silver in the product design category at the Brazil Design Awards (BDA), this machine is really raising the bar when it comes to programming.

“Unlike conventional controllers, PC-based control from Beckhoff offers its end-customers straightforward machine operation and flexible after-sales options. What’s more, any operational issues can be analysed remotely, directly from the plant, which minimises both time and manpower requirements.” De Mattos sees further advantages in the simplification of software upgrades, which can easily be integrated into existing control programmes for continuous equipment optimisation.

Back in 2013, Grazmec started developing a tractor for sowing that was designed to treat up to 30 000 kg of soybean sprouts per hour, as per the end-customer’s requirements. Electrical control units were already in use, although the required dosages were still very much determined by the mechanical system design. For this reason, the throughput times and quantities for seeds and chemicals had to be recorded as part of an elaborate calibration process before the machine was put into operation.

Despite the smooth operation, high seed flow rate and simple operation, the system was slow and complex, which resulted in several rounds of optimisations starting in 2015. These included better sensor technology, the option of using up to four liquid chemical products for seed treatment, touchscreen operation, storage of up to 10 formulations and product reservoirs.

Greater functionality and IoT communication

The second generation of machines was successful but was increasingly reaching its limits as customer requirements became more demanding and technology levels increased. This called for a further redesign of the machine concept in 2019, not only to make the system more flexible and straightforward, but also to facilitate software upgrades.

The CX5140 embedded PC from Beckhoff, with an Intel Atom quad-core processor running at 1,91 GHz and equipped with TwinCAT 3 automation software, provides the necessary computing power, while the associated I/O system is formed by EL1819 and EL2809 high-density (HD) digital input and output EtherCAT terminals.

The machine parameters can be conveniently accessed via a CP2916 multi-touch, built-in control panel with 15,6-inch display, optimally supported by the HTML 5-based operator interface created with a TF2000 TwinCAT HMI. As a result, significantly more formulations can now be stored with a greater number of liquid and powder components, extending flexibility in terms of machine functionality and usable seed. Moreover, manuals and demonstration videos are stored directly on the machine to simplify system operation, cutting down on process and maintenance times.

As part of Grazmec’s IoT strategy, the cost and consumption reports generated by the production control system open up new ways of managing and analysing data. With TwinCAT IoT communication provided by Beckhoff’s TF6701, the machine data is sent to the Grazmec server via the MQTT (MQ Telemetry Transport) protocol for this purpose. This can then be analysed together with information such as daily updates on the quantities of treated seed and consumed treatment compounds, allowing more informed decisions to be made in the process.

Other IoT benefits, according to Grazmec, include enhanced remote control and maintenance capabilities that also make the system more straightforward and efficient. De Mattos sums it up by saying, “The state-of-the-art control technology from Beckhoff will allow the devices to be used in entirely new applications. The TwinCAT software, in particular, opens up a wide range of possibilities when it comes to upgrades, continuous improvements, ease of use and excellent quality.”


Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Flexible EtherCAT communication interface for DALI-2
Beckhoff Automation Fieldbus & Industrial Networking
The EL6821 EtherCAT Terminal from Beckhoff allows up to 64 DALI/DALI-2 slaves and 64 DALI-2 input devices to be connected. The TwinCAT 3 System Manager makes it easy to configure and parameterise DALI devices flexibly.

Read more...
EtherCAT-based control technology for building automation
Beckhoff Automation Fieldbus & Industrial Networking
Modern non-residential buildings place many high demands on building automation. This can be optimally implemented with EtherCAT-based control technology from Beckhoff, which provides an efficient central automation architecture thanks to ultra-fast data communication.

Read more...
PC-based control for university studies
Beckhoff Automation Fieldbus & Industrial Networking
The IDEA box developed at Heilbronn University of Applied Sciences is designed to introduce students to the topic of Industry 4.0 in a simple and practical way. At the core of the corresponding demo case is PC-based control from Beckhoff.

Read more...
Understanding the role of AI in generative engineering design
System Integration & Control Systems Design
When a design engineer sets out to design a new part, component, or assembly, the intent is to meet the design requirements for fit, form and function, and also incorporate a certain degree of innovation and elegance to the overall design. There is no reason to re-invent the wheel by introducing a new design.

Read more...
PCS stays up so you don’t have to
PCS Global System Integration & Control Systems Design
Maybe it’s time to look at a solution that stays online 99,99999% of the time so you don’t have to. This the world of Stratus computer platforms, tailor-made for your critical applications.

Read more...
High-performance motion control for teabag packaging machine
Beckhoff Automation Editor's Choice
Teepak relies on PC-based control and drive technology from Beckhoff to set new benchmarks for speed and precision in its teabag packaging machines.

Read more...
Four ways the global parts shortage has led to innovation and openness
System Integration & Control Systems Design
For those who use automation parts, the unpredictable nature of the supply chain is one of the biggest problems faced today. The shortfall has impacted every industry, but automation components have been especially affected.

Read more...
Complete system for transparent energy monitoring
Beckhoff Automation Editor's Choice Electrical Power & Protection
Transparent energy monitoring reduces both machine downtime and the necessity to oversize the corresponding components. Added to these advantages are simplified preventive maintenance, and increased production efficiency. The wide range of PC-based control technology from Beckhoff offers a solution that can be optimally adapted to individual applications.

Read more...
Iritron’s year of consolidation
Iritron Editor's Choice System Integration & Control Systems Design
Despite the multiple challenges faced by businesses in South Africa, the buoyancy of the technology sector worldwide has produced some green shoots for automation specialist, Iritron.

Read more...
Five edge opportunities for SIs to maximise revenue in 2024
Editor's Choice System Integration & Control Systems Design
System integrators continue to face the challenge of doing more with less – supporting complex operations, while meeting production schedules with limited resources, and innovating to increase efficiency, maximise safety and reduce risk.

Read more...