Automation of BSU. Comprehensive modernization of a concrete plant

Home Modernization and reconstruction of BSU A concrete mixing plant (BSU) is a balanced system of stationary equipment designed to carry out the full cycle of concrete preparation. The standard cycle begins with the delivery of the necessary components to the mixing plant: bulk (sand, crushed stone) and binders (cement), provides for their storage, mixing in the required proportions according to the technological recipe, and unloading of the finished product (concrete). Concrete mixing plants can operate for a long time and serve a large number of construction projects. At the same time, equipment that is critical for the quality of work and its trouble-free operation (namely, elements of the dosing, monitoring and control system) becomes obsolete much faster than the actuators of the BSU complex. Based on this, the most rational choice from the point of view of production efficiency and cost savings is not the purchase of a new one, but the reconstruction and modernization and accompanying automation of the existing BSU.

Reconstruction and modernization of RBU and BSU of a concrete plant

Modernization of a batching plant is a complex technological process that begins with an inspection of the facility and ends not only with the installation and commissioning of the necessary equipment, but also with training of personnel to work in the changed conditions of modernized production. It is precisely these services, turnkey modernization of the BSU, that the company IC PROMSERVICE offers. It must be emphasized that the modernization of BSU is not just a fashionable trend, but a real contribution to business profitability. Concrete and mortars produced on sites equipped with outdated dosing and control systems often do not meet the standards of GOST 7473-94. The cost of such products is high (due to losses associated with the influence of the “human factor”, increased consumption of cement and inert materials, and banal thefts at the stage of shipment of ready-made mixtures). The “heart” of modernizing the control system of the concrete plant and reinforced concrete plant is the automated control system (ACS). It is the company IC PROMSERVICE that offers a system for automating batching plants that is unique on the CIS market. Developed taking into account European and Russian standards, carefully tested based on many years of experience in use, reliable and durable, the ACS BSU from the company IC PROMSERVIS is also one of the most inexpensive on the market!

Implementation of a control and alarm system for BSU and RBU of a concrete plant and a reinforced concrete plant

The main elements of the reconstruction and modernization of the BSU are the replacement of the weighing system for dosed components (strain gauge system, which includes strain gauges, strain gauge modules, etc.), actuators (gates, valves, etc.), pneumatic equipment, dispensers of the necessary components, controllers and other elements automatic control systems (or their initial installation). Also, the concept of modernization and automation of the BSU includes equipping the plant operator’s workplace with a new modern control panel. If necessary and if the customer wishes, equipment intended for receiving, transporting and storing bulk materials is also replaced; Cement warehouses and equipment for unloading finished products are being modernized and automated.

The BSU complex, in addition to the necessary equipment (concrete and mortar mixers, dispensers of bulk and liquid substances, tanks for storing bulk materials, cement warehouses and other devices for service purposes), must be equipped with control and accounting systems. These systems can be either completely manual (in which case they are heavily dependent on the “human factor”), or semi-automatic or automatic.

Modernization of BSU is our specialization!

The company IC PROMSERVICE was created in 1998 as an enterprise to solve the problems of modernizing concrete production in Russia and the CIS countries. Therefore, the main specialization of IC PROMSERVICE remains the reconstruction and modernization of concrete and asphalt concrete plants. Thanks to the work of the engineering and design staff, IC PROMSERVICE has rightfully won a leading position among companies specializing in the modernization of concrete production. The company's equipment successfully operates at more than 100 enterprises in Russia and the CIS countries. Our company’s engineers, based on many years of experience, will offer ready-made solutions for installing new or upgrading existing technological equipment at construction enterprises. We have our own design department, production base, ACS (Automated Control System) department and a commissioning area. We independently manufacture automated weighing dispensers for cement, water, chemical additives, sand, crushed stone and expanded clay. The quality of commercial products prepared on our equipment meets the requirements of GOST 7473-94.

Content

• What can cause RBU equipment failure?
• Types of repairs
• What most often needs to be repaired?
• What is BSU maintenance?
• Modernization of RBU during repairs

Modern concrete plants are high-tech equipment for concrete production, manufactured using innovative technologies.

Despite the high quality of RBU, parts that bear intense loads wear out over time and require replacement.

Mobile concrete plants consist of collapsible structural units. If one of the structural elements breaks down, original spare parts and special tools are required for repairs. The manufacturing plant is the main supplier of spare parts. Therefore, in the event of an unforeseen situation, it is best to contact the company that develops and produces this equipment.

Highly qualified personnel is the key to success

To fulfill its obligations to clients, PROMSERVICE IC has highly qualified personnel. The company's engineering personnel constantly improve their professional level through courses and seminars both in Russia and at leading engineering enterprises in Western Europe. Therefore, the company IC PROMSERVIS offers unsurpassed European quality and technology at reasonable prices. Thus, an important advantage of PROMSERVICE solutions is their cost. If all the necessary functions are available, the BSU automated control system from IC PROMSERVIS is 2-3 times cheaper than its competitors. In this case, the warranty on the control system is established for a period of 3 (THREE!) years from the date of start of operation.

More than 100 implemented projects

If you do not want yours for companies that are taking their first steps in modernizing concrete production, entrust the modernization process to the company IC PROMSERVICE, which has more than 100 equipped enterprises in Russia and other CIS countries. The experience of ten years of successful modernization carried out by IC PROMSERVICE will work to increase the profitability of your business.

Implementation of the necessary technological interlocks to eliminate emergency situations of dosing and mixing equipment;

• Automatic and manual modes of production.

• 
  Optimal control of weighing equipment;

• Visualization of the state of technological equipment;
• Multi-pass parallel mode of component dosing;
• Access control system;
• Automatic printing of invoices and quality certificates;
• Organization of several workplaces according to the principle: LABORATORY ASSISTANT-DISPATCHER-BSU OPERATOR;
• Video surveillance system for the operation of the most critical mechanisms;
• Automatic distribution of the necessary information (number of cubes, consumption of components, etc.) to the required GSM (cellular) phone numbers in the form of SMS messages;
• Accurate accounting of component dosing both automatically and manually;
• Possibility of automatic correction of the amount of chemical additives (CAA) in winter depending on the outside air temperature according to a given schedule;
• Control of material consumption from supply bins;
• Monitoring the level of cement in cement silos (hoppers) in % or tons, visually displaying the receipt and consumption of cement in the form of a time graph;
• Unlimited number of recipes in the database;
• Breakdown of recipes into groups (summer, winter, production, ready-mixed concrete, etc.). The number of groups is unlimited;
• The mixing time and the time for unloading from the mixer are indicated in each recipe individually for each recipe or for each group of recipes;
• Creation of various reports on shipments made;
• Accounting part of the program;
• Automatic adjustment of the water-cement ratio depending on the moisture content of the aggregates;
• Control of mixture mobility;
• Intelligent skip lift control system;
• Sensors for monitoring the movement of the conveyor belt;
• Possibility of dosing materials both by weight and volume.

Great functionality and low cost

The automatic control system we developed is a unique offer on the Russian automation market. Having a low cost, the ACS system has great functionality and enormous reliability, because during its development, all components of the ACS BSU system undergo thorough testing, input and output control. The system modules fit together flawlessly, and during the installation process there is no need to modify anything on site. Installation time is reduced to a minimum, while the transition to a new, reconstructed system occurs without stopping production! At the end of the warranty period, the BSU and control system are accepted for service under a separate agreement. Special attention is always paid to new European and Russian standards; all equipment has appropriate certificates, which serves as a reliable guarantee of compliance with all safety standards of manufactured equipment. Therefore, decisions on modernizing the BSU are balanced, well-balanced and have low costs. Well-established relationships with leading suppliers and manufacturers of modern equipment for the mechanical and pneumatic parts of BSU systems make it possible to reduce the time required for completing work to the required minimum, and, as a rule, range from 1 to 3 weeks.

What can cause RBU equipment failure?

1. Service life has expired. No matter how high-quality and reliable a part is, over time it wears out and requires repair or replacement. Units under constant, intense load fail especially quickly.
2. Incorrect operation. It is important to follow the rules for operating the equipment. The main components of a concrete plant must undergo regular maintenance and be maintained in a clean, serviceable condition.
3. Unprofessional installation. Modern mobile RBUs ​​consist of collapsible elements. Structural units are assembled using bolted connections without welding. Assembly must be carried out by specialists using special equipment. Professional, high-quality installation is the key to long-term, uninterrupted operation of the BSU,

Generalized algorithm for working with the system

When a new order is received for a solution or concrete of a certain brand (recipe), the dispatcher issues a delivery note to the driver of the vehicle (VV), indicating the recipe and the amount of the mixture (in m3). Data on the number of components (Recipes) is entered and edited by a laboratory assistant; for each recipe, he indicates the amount of cement, water, sand, chemicals. additives and crushed stone. The history of changing/deleting recipes is stored in a database (DB).

With the received invoice, the driver is sent for loading. The operator sees the number of the automixer (dump truck) through a video camera, selects an application from the queue of applications that corresponds to the invoice and starts the process of preparing the mixture and loading it into the vehicle.

The possibility of autonomous operation of the operator is provided in case of lack of communication with the dispatcher and laboratory assistant. When communication is restored, the databases of the dispatcher, laboratory assistant and operator are synchronized. In offline mode, the operator selects a recipe from the local database and indicates the amount of mixture (in m3), and also has the opportunity, if necessary, to edit an existing recipe (or add a new one). The history of changing/deleting local recipes is stored in a database (DB).

Description and features of RBU-Mini:

• Capacity up to 10 cubic meters. hour.
• SB series forced concrete mixer.
• Small overall dimensions.
• Possibility to change and supplement the package.
• Basic warranty 12 months, extended 24 months (ask when placing an order).

No “hidden fees”

Are you skeptical of low-cost claims and are concerned about increased costs due to hidden additional fees? Just not with the company IC PROMSERVICE. The company values ​​its reputation, and therefore the preparation of estimates and issuance of commercial proposals is organized as transparently as possible for clients. The cost of equipment and work is announced at the stage of developing a modernization project, based on the results of a thorough examination of your production and an assessment of its real condition. Unforeseen and additional payments are excluded.

Availability of production base

Having our own production base is another important advantage of cooperation with the company IC PROMSERVICE. The company manufactures some of the equipment independently, which provides customers with a guarantee of quality, compliance with European and Russian standards and the most favorable price. The rest of the equipment is purchased exclusively from leading suppliers, proven by many years of successful cooperation. Work on your site will never get stuck halfway due to lack of necessary equipment and will be completed in record time. Upgrade in one to three weeks? Only the company IC PROMSERVICE can offer such terms.

THREE YEAR WARRANTY

The IC PROMSERVICE company is so confident in the quality of the equipment provided and the qualifications of the specialists who install it that it provides a guarantee on the control system for THREE years!

But this is not all the benefits that you can get by cooperating with the company IC PROMSERVICE. After upgrading the BSU, you will have access to such features as printing invoices and other documents and reports automatically, the ability to choose between operating modes (manual, automatic and semi-automatic), creating a database with any number of mixture recipes you need, which you can break into groups.

If you have already planned a modernization, but are worried that the work will cost you too much, you need to contact the PROMSERVICE IC company. A wide selection of ready-made engineering solutions and qualified employees who have been trained at European enterprises and have extensive experience - this is a guarantee of choosing the most optimal modernization option specifically for your production. Only with the company IC PROMSERVIS you can be sure of minimal costs and the fastest possible recovery due to a noticeable increase in the quality of the finished product and a reduction in losses at the stage of dosing the necessary components for loading into the mixer. Based on the results of modernization and automation of the BSU, the productivity of the installation increases on average by 20-25%!

Types of RBU repairs