Something New: PLC to Embedded
We've been holding this in for quite some time. We're stoked to announce we've just launched production on a hot box control panel project for KM International. It began thanks to Covid supply chain issues after KMI called us to ask about embedded solutions because he couldn't source the PLC they had been using anymore. Our answer was obviously, "heck yea we can build you something!"
Since that conversation we've successfully designed, prototyped, and field tested a brand-spankin-new hot box controller to replace the complicated and expensive PLC-based system they had before.
The new design is a custom embedded solution, customized to fit in the exact same footprint as the old control panel to minimize equipment build impacts. We opted for a Microchip powered embedded processor, thermocouple ICs from Analog Devices, and a fully isolated power supply from Recom.
The system monitors two thermocouple probes (asphalt chamber and combustion chamber) and enables the gas burner signal to heat up the material bin. Our custom controller integrates with an emergency stop switch to kill the enable signal but keep the control panel live. If the combustion chamber gets too hot, the system will drop the enable signal and notify nearby operators.
Our favorite part about the unit is the $75 solid state relay we eliminated in favor of a $15 mechanical timer switch for the backup signal. If the controller fails for any reason the operator can swap the burner wire harness, twist the timer knob, and keep the system running long enough to finish the asphalt job.
Of course, the rotary encoder is pretty cool too.
We're on pace to build 200 units a year now. The best part ... KMI pays $1,800 LESS per unit compared to their other control panel. Their development fee payoff is 17 units. Less than one months' worth of control panels. The math shakes out to saving KMI $360k PER YEAR.
We've turned what started as a supply chain challenge into a cost saving monster.
If you're building control panels with PLCs that don't really need to be done that way, give us a holler and let's see if we can save you a metric ton of money.