The on-line instrument, as its name suggests, is a high-precision instrument that is installed on the production line to detect samples that flow through the production line pipe or tank and ensure the normality of the sample's pass rate and production process. Increasing the production efficiency through on-line instrumentation and automated production equipment is a major trend in the future of China's industrial development. Its specific practical significance includes: online implementation of monitoring, high degree of manual automation, more intuitive guidance of the process personnel to operate, reduce labor costs, reduce the production costs of the entity, more efficient guarantee of product quality. Many domestic brand-name companies are doing online product control.
The use of CM-800a online concentration meter or PRM-100a on - line measurement and control system in the liquid production line process enables real-time detection and control of the entire process, comprehensively improving the process reproducibility and quality stability of the production process, and completely changing the long-term use of artificial The extensive production management methods of operating experience, manual recording, and manual control ensure that the process is strictly executed in accordance with the process plan, so as to ensure that the product quality reaches the international advanced level. At the same time, accurate control can prevent excessive use of water, raw materials, and energy. To achieve the goal of energy conservation, emission reduction and environmental protection.
The significance of on-line real-time monitoring : production-oriented companies will inevitably cause defective products in the production process, and the reasons for causing inferior products include: CIP pollution, equipment failures, detection errors, defective products in the previous phase, and other reasons. . The solution can be roughly attributed to on-line real-time monitoring of concentration changes, automatic detection to eliminate human errors, individual control of each process step, and enhancement of the overall process flexibility, avoiding a single process step and affecting the entire process chain.
The degree of manual automation is of high significance : As a production-oriented enterprise, production efficiency represents the production strength, and the greatest guarantee of production efficiency is manual. Employees who have mastered automated production techniques to a high degree are the most important factors in improving production efficiency and ensuring product quality.
Intuitive guidance of production personnel operations : In the past, traditional enterprises, workers in the production of guidance operation is the guidance of human experience, mature staff and new staff are using word of mouth for the transfer of operating experience, However, it is very difficult to avoid unnecessary operational inaccuracies in the production line because the reference standards are different. Therefore, in a production enterprise, it is very necessary to have a more scientific and reliable inspection method to test the correctness of the staff experience, and to unify the standards of the company's production line in order to achieve efficient production.
Labor costs : Labor-related costs are now one of the most important factors for measuring the profitability of companies. Because with the progress of society, people’s living standards have improved, and the relevance of national policies has led to a large labor cost in on-site production companies. The growth rate, which includes the increase in the salaries of employees and the protection of social welfare, has brought great pressure on the company. Colleagues are facing internal costs and social competition. Under the double pressure, many companies are overwhelmed, and even some small businesses are Failure, so reducing labor costs is especially important for a development-oriented production company. Because some enterprises that use more automation in foreign countries are very strict in terms of personnel control, they are roughly 1/5 of domestic companies and even some 1/10 of the same size companies in China . However, the production efficiency is 2-3 times that of domestic companies . This is because domestic products are vulnerable to the price of foreign products.
Production cost and product quality control : In order to maximize profit in the enterprise, it is necessary to strictly control the production cost, and to ensure the most efficient product quality. Online industrial automation control is the intuitive embodiment of both. The higher the degree of automation is, the higher the corresponding production efficiency and quality control quality are. The lower the degree of automation, the more gradually the company will be eliminated from the natural environment of the company.
Industry application:
1 , corn starch syrup processing
2 , cane sugar
ATAGO 's online saccharinometer CM-800a has been used in a large number of applications in the industry, online control of finished sugar, sugar content in the mixing and fermentation process, and the use of crystallized crystalline sugars to precisely control the quality of finished sugar. PRM-100a online measurement and control system 0-100% of the full range to meet the concentration requirements of various points. Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â 
Sugar cane mature judgment standard brix value exceeds 13%, ATAGO PAL handheld refractometer Brix MASTER and accurate measurement can be very intuitive brix value criteria to determine sugarcane harvest.
Sugar cane raw materials in the sugar mill are first broken into strips or strips to make sugar cane, which is then sent to the press for squeezing. Pressed sugarcane juice is cleaned by sulfite purification, pre-ashing and heating, sulfur-neutralization, sedimentation and filtration. The concentration of clear juice is approximately 12-14 Brix , and the clear juice must be concentrated by multiple-effect evaporation to 60%. Brix 's syrup is sulfurated and filtered to make pure syrup. The pure syrup is boiled, crystallized, centrifuged and dried to make raw sugar.
ATAGO 's on- line glucometer is installed through a pipeline bypass, installed online at the heater, filter filter, and evaporator outlet. It can also be installed in the tank to monitor sugar content during evaporation and improve evaporation efficiency.
The machining quality of mechanical parts is good or bad , and the precision of processing is high . In addition to the raw materials used , the mechanical processing equipment is an important factor. However, during machining, in addition to equipment and tool used, cutting oil (fluid) using the selection part becomes the most important. How to deal with the complex and complex mechanical processing methods , especially the popularization and use of various CNC processing equipment , in the continuous processing of its high speed, high quality, low input, high output , high processing accuracy, high surface roughness development At the same time , taking into account the reduction in the labor intensity of workers and the reduction of environmental pollution , the cutting oil concentration must be effectively regulated in order to achieve the best economic benefits of machining.
The ATAGO online concentration meter can be installed on an external circulating pipe to realize on-line detection of the concentration of the cutting fluid and the cooling fluid to control the surface quality and machining accuracy in the precision machining process. The instrument output 4-20mA analog signal can be used for remote control. If the oil film adhesion phenomenon occurs during the deployment process, ATAGO's latest development of an automatic mechanical cleaning prism system can solve such problems.
4. Beverages (the main application point sugaring workshop sugar process section)
The figure above shows the application of on- line sugar meter to the on- line monitoring of sugar content in the filling production line of functional beverages. In the production process of functional beverages and herbal tea beverages, during the sugar filling process before the finished product filling, the national standard is for soluble solids (sugar content). there are strict measurement, similar to Red Bull Brix value measurement in the range of 11.2% - 11.7%, JDB Wong Lo Kat herbal tea such as measurement range of 8.5% - 9.3%.
ATAGO Online Concentration Meter CM-800a can precisely control the sugar content value of the production line within the required range, and can output 4-20mA current signal feedback to the control system (shown in the upper right figure), below the lower limit or above the upper limit output alarm , control the pump start or stop, to achieve automated filling production.
5 , food
In the soy protein production process chain, the neutralization process is very important. Controlling the concentration value of the neutralization process and the amount of water added to the lye directly leads to the efficiency and quality of the finished product. The dry matter content can be used to control the amount of alkali and water added. The concentration of most solids is controlled between 10% and 17% . Therefore, the online concentration of the neutralization process pipeline pump outlet and the neutralization tank circulation pipeline (Solid content) detection can be controlled more precisely at a concentration of 14.5-16.0% , so that the quality of the finished product (fans, yuba, etc.) can be controlled more accurately and high-quality, high-efficiency production can be achieved.
ATAG0 online concentration meter is installed on the outlet of the neutralization tank pump and in the middle and circulation pipeline by means of pipeline installation. The solid content concentration of the soy protein is detected online and the concentration value is transmitted far to the DCS .
ATAGO online concentration meter can measure 0-100% of full scale , due to production environment requirements.
6. Jams (Xinjiang, Shaanxi, Ningxia)
The Ketchup finished product concentration is approximately controlled at 28-30% and 36-38% BRIX value. The ATAGO Online Concentration Meter CM-800a can be installed at the outlet of each of the three-effect evaporator circulation pumps, respectively. , 5b , 5c position, the installation method is bypass piping installation, can monitor the current concentration value of each effect of tomato processing in real time, the instrument concentration value can be converted into 4-20mA current line number into the control system, or PLC is used for precise integration control, improving production efficiency, effectively reducing production costs and increasing production efficiency.
7 , chemical industry
Working principle: The use of solvents (such as water) for the strong absorption of harmful or valuable components (such as DMF or DMAC ) in the exhaust gas, to purify the exhaust gas to meet the emission standards, or to recover valuable components and recycle them after purification by distillation. , or both purification and recycling purposes.
The ATAGO online concentration meter CM-800a is installed on the first circulation loop. The absorption solvent (such as water) in this section comes from the second loop, and the solvent has absorbed the target components in the exhaust gas in the second loop loop. When the first cycle loop is further absorbed, the solvent absorption capacity will be reduced. The ATAGO Concentration Meter CM-800a can immediately monitor the target components in the solvent, determine the solvent absorption ability of the target component , and determine whether to increase the fresh absorption solvent to improve Absorption efficiency.
Because the density of the solution and the density of water are basically the same, it is not feasible to measure the density and mass flowmeter in this case. The ATAGO online concentration meter CM-800a can effectively and stably measure the concentration of the solution, through 4- 20mA analog signal transmission.
Recently, ATAGO (Atago) of all online concentration meter in the overall performance of a comprehensive upgrade of water level detection part referred to the level of IP 67, IP 67 can be applied to outdoor plant environments: IP64 not, avoid high humidity IP 67 The water seepage phenomenon occurs in the environment. The IP 67 withstands the exchange temperature. Since the IP 64 is 5-40°C , the IP 67 dust-proof performance is higher than that of the IP64 .
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