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Procedia Manufacturing 32 (2019) 545–552
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The
The 12th
12th International
International Conference
Conference Interdisciplinarity
Interdisciplinarity in
in Engineering
Engineering

Development
Development of of aa Monitoring
Monitoring and and Control
Control System
System for
for
Timber’s
Timber’s
Manufacturing Engineering Society Drying
International Process
Drying Process
Conference 2017, MESIC 2017, 28-30 June
2017, Vigo (Pontevedra), Spain
a, b
Mircea
Mircea Dulău
Dulăua, *,
*, Istvan
Istvan Madaras
Madarasb
Costing models for capacity optimization in Industry 4.0: Trade-off
0F

0F

a
“Petru Maior” University of Tîrgu-Mureș, N. Iorga no.1, Tîrgu-Mureș, 540088, Romania
a
“Petru Maior” University of Tîrgu-Mureș, N. Iorga no.1, Tîrgu-Mureș, 540088, Romania
between S.C. used capacity andno. 56,
operational efficiency
b
Larix Mobila S.R.L., Iernuțeni no. 56, Reghin, 545300, Romania
b
S.C. Larix Mobila S.R.L., Iernuțeni Reghin, 545300, Romania

A. Santanaa, P. Afonsoa,*, A. Zaninb, R. Wernkeb


Abstract
Abstract a
University of Minho, 4800-058 Guimarães, Portugal
The timber’s drying process is very important
b
in reducing
Unochapecó, the wood
89809-000 lossesSC,and
Chapecó, in improving the quality of the final products
Brazil
The timber’s drying process is very important in reducing the wood losses and in improving the quality of the final products
made of wood. Taking into consideration that the quality of the timber is directly related to the moisture content of the wood, the
made of wood. Taking into consideration that the quality of the timber is directly related to the moisture content of the wood, the
main problem refers to the control of the temperature and relative moisture in the drying chamber. Therefore, in order to fulfill
main problem refers to the control of the temperature and relative moisture in the drying chamber. Therefore, in order to fulfill
these requirements, the automatic control strategies are needed, including the reducing of the energy consumption. The present
these requirements, the automatic control strategies are needed, including the reducing of the energy consumption. The present
Abstract
paper highlights the components of the timber’s drying system, the design and the implementation of the On-Off control strategy
paper highlights the components of the timber’s drying system, the design and the implementation of the On-Off control strategy
and the monitoring interface.
and the monitoring
Under the concept interface.
of "Industry 4.0", production processes will be pushed to be increasingly interconnected,
information
© 2018The based on
2019 TheAuthors.
Authors. a real time
Published
Published by basis Ltd.
byElsevier
Elsevier and,
Ltd. necessarily, much more efficient. In this context, capacity optimization
© 2018The Authors. Published by Elsevier Ltd.
goes beyond
This is an openthe traditional
access aim
article under of
thecapacity maximization,
CC BY-NC-ND contributing also for organization’s profitability and value.
license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Indeed,
Selection lean management
and peer-review underand continuous
responsibility improvement
of the approaches
12th International Conferencesuggest capacity optimization
Interdisciplinarity in Engineering.instead of
Selection and peer-review under responsibility of the 12th International Conference Interdisciplinarity in Engineering.
maximization. The study of capacity optimization and costing models is an important research topic that deserves
Keywords: timberfrom
contributions drying; kilnthe
both drying; moistureand
practical content; on-off control.
theoretical perspectives. This paper presents and discusses a mathematical
Keywords: timber drying; kiln drying; moisture content; on-off control.
model for capacity management based on different costing models (ABC and TDABC). A generic model has been
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
1. Introduction
1. Introduction
value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity
optimization might hide operational inefficiency.
Nowadays, considering the necessity of efficiency and improvement of the final product’s quality, the precise
Nowadays,
© 2017 considering
The Authors. Publishedtheby necessity
Elsevier B.V.of efficiency and improvement of the final product’s quality, the precise
control of
Peer-review the industrial processes’ parameters (e.g.,oftemperature, moisture, pressure, flow etc.) is aConference
mandatory
control of under responsibility
the industrial of the scientific
processes’ committee
parameters the Manufacturing
(e.g., temperature, Engineering
moisture, Society
pressure, International
flow etc.) is a mandatory
operation. The fulfilling of these requirements implies the necessity of adequate strategies.
2017.
operation. The fulfilling of these requirements implies the necessity of adequate strategies.
The control strategies in which the command signal can take only two values (On-Off or switching controllers)
The control strategies in which the command signal can take only two values (On-Off or switching controllers)
are commonly
Keywords: used ABC;
Cost Models; because
TDABC;of their simplicity
Capacity (simple
Management; relay orOperational
Idle Capacity; electronic relay) and energy efficiency of their high
are commonly used because of their simplicity (simple relay or electronicEfficiency
relay) and energy efficiency of their high

1. Introduction
* Corresponding author. Tel.: 04-075-224-9499; fax: 04-026-523-3210.
* The
Corresponding
cost author.
of idle Tel.: 04-075-224-9499;
capacity fax: 04-026-523-3210.
is a fundamental information for companies and their management of extreme importance
E-mail address: mircea.dulau@ing.upm.ro
E-mail address: mircea.dulau@ing.upm.ro
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
in several ways:
2351-9789© 2018Thetons of production,
Authors. available
Published by Elsevier Ltd. hours of manufacturing, etc. The management of the idle capacity
2351-9789© 2018The Authors. Published by Elsevier Ltd.
This is anAfonso.
* Paulo open access
Tel.:article under
+351 253 510the761;
CC BY-NC-ND
+351 253license(https://creativecommons.org/licenses/by-nc-nd/4.0/)
This is an open access article under the CC fax:
BY-NC-ND 604 741
license(https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection
E-mail and peer-review
address: under responsibility of the 12th International Conference Interdisciplinarity in Engineering.
psafonso@dps.uminho.pt
Selection and peer-review under responsibility of the 12th International Conference Interdisciplinarity in Engineering.

2351-9789 © 2017 The Authors. Published by Elsevier B.V.


Peer-review
2351-9789 © under
2019responsibility
The Authors. of the scientificbycommittee
Published Elsevier of the Manufacturing Engineering Society International Conference 2017.
Ltd.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection and peer-review under responsibility of the 12th International Conference Interdisciplinarity in Engineering.
10.1016/j.promfg.2019.02.251
546 Mircea Dulău et al. / Procedia Manufacturing 32 (2019) 545–552
2 Mircea Dulău and Istvan Madaras/ Procedia Manufacturing 00 (2018) 000–000

power output signal.


In this context, for the wood’s drying systems, characterized by large time constants, the control strategies such
as On-Off and/or PID are recommended.
In this paper, the authors propose a strategy of development, monitoring and control of a timber’s drying system,
using a programmable controller (Siemens) and dedicated devices and software (Step 7), such that the moisture
content of the timber will be stabilized at the set-point value.
This study is complementary with the study [1], which presents the block diagram of the drying system (without
detailing the components), the operating of a timber’s drying system, the drying phases and the implementation of
an automatic system designed for the control of the drying operations.
The field’s literature highlights similar studies and experiments, related to the problem of timber’s drying
processes. The embedding of this knowledge in the control systems allowed the optimization of the drying regimes
and also the improvement of the drying quality.
So, the manuals [2,3] focus on drying methods for timber of different thicknesses (with minimal drying defects),
including pre-drying treatments that reduce defects and improve drying quality, respectively the temperature and
moisture transfer, the timber’s drying processes, as well as a series of drying equipments. A mathematical model
used for the numerical simulation of the (convective) drying process, developed and presented in [4], is based on the
combination of the temperature, speed and relative moisture. For the wood’s drying, a relationship between the
temperature-moisture model and the control signal, based on a neural network, is studied in [5]. A predictive model,
depending on the drying temperature and the equilibrium moisture, is built in [6]. The paper [7] presents the
developing of an adaptive control system for the timber’s drying, based on the moisture content of the wood, on the
environment and relative moistures. Different sensors for the timber’s moisture monitoring, used in the heating kiln,
based on the electrical conductivity, were tested and presented in [8]. Also, the moisture characteristics, based on the
electrical resistance of the wood, were tested in [9].
A robust control system developed for a wood drying kiln, in order to assure the moisture content stability to an
imposed value, is investigated in [10]. The control methods based on neural network and PID controllers can
improve the automation of the wood drying industry, according to the study [10]. An input-state-output approach of
the wood’s drying process modeling is considered in [11]. The moisture content and the temperature behavior of the
timber inside a drying kiln are based on the balance equations for the energy and mass. The paper [12] investigates
the development and evaluation of an intelligent control system for a wood’s drying kiln process incorporating
diagonal recurrent network and proportional-integral-derivative (PID) control. The elements of design and
implementation using microprocessors, the set of instructions, the organizing and addressing of the memory, the
interruption system etc., are developed in [13]. The basics of the PID and the On-Off control algorithms with the
tuning criteria are presented in [14]. The paper [15] analyses the On-Off controllers, assuming that the control
quality can be described by the period, the amplitude and the mean value of the controlled signal. Also, the paper
proposes a structure of the implementation using the ladder logic language of the S7-1200 PLC.
In this section of the paper it is highlighted a short review of studies on timber’s drying systems, as presented in
the literature. In Section 2, the block diagram of the timber’s drying system, including heating, ventilating and air
evacuating components, is presented. In Section 3, the design and implementation of the On-Off control system,
respectively the monitoring interface, are detailed. The final considerations are provided in Conclusions section.

2. Design of the timber’s drying system

About 85% of the timber’s drying industrial equipment work based on the conventional process, through hot air
convection, under 100oC and atmospheric pressure. The principle of the conventional drying involves the air forced
circulation through the timber stack with the help of the fans and the heat exchangers. This way ensures the heat
transfer to the wood and the moisture takeover from the wood. The excess moisture from the air is eliminated
through the exhausts with adjustable flaps, simultaneously being admitted an equal quantity of fresh air. The
moistening of the air can be done with vapors or cold water, sprayed through nozzle.
In order to assure all the mentioned functions involved in the drying process, the drying installation is equipped
with systems for: heating, ventilation, air evacuating, command and monitoring (Fig. 1).
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The heating system consists of: water tank (heated with electrical resistance, Rh), pump for water recirculation,
water-air heat-exchanger (Fig. 2).
Through the timber stack it is necessary to assure the uniform circulation of the air (about 1m/s). So, with the
fans, the ventilating system transfers the heat from the environment to the timber and takes over the moisture
(eliminated from the timber, Fig. 2).
In order to remove the moisture and to assure the air exchange between the drying chamber and outdoors, the
evacuating system uses the intake and exhaust with flaps (Fig. 3).

Drying chamber

Ventilating
system

Air evacuating Command


system panel
Monitoring
Heating system
system

Fig. 1. Block diagram of the drying system.

Water
tank Pump
Stack timber

Rh Heat
M
exchanger

Fig. 2. Block diagrams of the heating and ventilating systems.

Intake and exhaust


with flaps

M M Chamber
wall

Fig. 3. Block diagram of the intake and exhaust system.


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The control of the system is made using the Siemens programmable controller, connected to the additional
devices. It highlights: CPU 313C, Profibus CP342-5 communication, DO16xDC24V/0.5A digital output module,
AI8x12Bit analogical input module, 220V AC/24V DC power supply, module with 8 relays.

3. Design and implementation of the control system

The control of the temperature inside the drying chamber is made using a software implemented On-Off
controller (Fig. 4). The algorithm considers the difference between the real value of the measured temperature and
the set-point value specified by the drying recipe. So:
• if the temperature inside the drying chamber is lower than the set-point value, the recirculation pump is coupled;
• if the temperature inside the drying chamber is higher than the set-point value, the recirculation pump is
decoupled.
According to the Fig. 5, the control of the thermal agent temperature is also made by a software implemented
On-Off controller. For the heating it is used an electrical resistance, supplied through an opto-coupler and a relay
connected to the controller’s output.
In the closed-loop control diagram from the Fig. 6, the algorithm considers the difference between the calculated
equilibrium moisture and the set-point value, specified according to the drying recipe. In order to control the
closing-opening of the flaps, dc servos, relays and a microcontroler are used. So:
• if the equilibrium moisture is higher than the set-point value, the intake-exhaust flaps are opening;
• if the equilibrium moisture is lower than the set-point value, the intake-exhaust flaps are closing.
The On-Off controller considers (Fig. 7): V_P – the process value; S_P – the set-point value; delta – the
controller hysteresis; start – the starting condition for the drying cycle; output – the command signal.
E.g., if the start condition is valid, the maximum and minimum values for the hysteresis (delpa_up, delta_down) are
calculated. These values are compared to the V_P value and, depending on the result, the output of the controller
(command) is set/reset.

Temp. On-Off Drying Temp.


Pump chamber
set-point controller
_

Temp.
sensor

Fig. 4. Closed-loop system of the air temperature control.

Temp. On-Off Heating Water Temp.


set-point controller element tank
_

Temp.
sensor

Fig. 5. Closed-loop system of the water temperature control.


Mircea
Mircea Dulău DulăuMadaras/
and Istvan et al. / Procedia Manufacturing
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Air relative
Moisture On-Off Drying moisture
Flaps chamber
set-point controller
_

Eq. moisture Moisture


calculus sensor

Fig. 6. Closed-loop system of the equilibrium moisture control.

Fig. 7. The internal structure of the On-Off controller.

In the presented control structures, the measurement of the air moisture is made by a Honeywell sensor, HIH
4000-003, with: power supply of 5V; operational temperature between (- 40...+85)°C; range between (0-100)%;
response time of 15 sec., for slow air flow and temperature of 25°C; accuracy of ±3.5% for 25°C. The real value of
the moisture is a function of the output voltage of the sensor, corrected with a compensation formula [1]. The
measurements of the air temperature and thermal agent are made by PT 100 sensors, with: range of (-50…200)°C;
electrical resistance of 100Ω for 0°C. The analogical input of the PLC cannot read the resistance values over 600Ω,
so a voltage divisor is used in order to measure the wood resistance, then the wood moisture is determined [1,9]. The
mathematical method of equilibrium moisture determination is more precise and allows the real time monitoring
(e.g., for the temperature of 70oC, it results a value of 5.87% for the equilibrium moisture).
The monitoring system (Siemens WinCC) highlights four pages: Process, Recipes, Graphics and Service (Fig. 8)
[16]. The Process page displays the timber and equilibrium moistures, the air temperature and moisture, the set-point
values for the moisture and the temperature [1].
From the Recipes page, the human operator can choose an existing recipe of drying (e.g., beech and oak) or can
define the drying parameters, depending on the wood species (Fig. 9).
The interface has a Service page, with access rights only for the admin. Through this page, he can start the fans,
the recirculation pump and the heating system. Also, the page allows the manually control of the fans’ speed, the
flaps position and the changing of the controller’s parameters (Fig. 9).
The real time evolution of the timber’s moisture, the chamber’s temperature, the equilibrium moisture and the air
relative moisture can be displayed in the Graphics page (Fig. 10).
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Fig. 8. The Process page [1].

Fig. 9. The Recipe page overlapped the Service page.


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Fig. 10. The Graphics page.

4. Conclusions

The timber’s drying process has the most important role in improving the quality of wood and in increasing the
utilization of the wood in the final products. The key of these requirements refers to the control of the temperature
and equilibrium moisture in the drying chamber. The final value of the moisture up to which the timber has to be
dried depends on the final destination of the product. E.g.: (9-12)% for the furniture made of massive wood;
(13-15)% for windows and exterior doors; (6-8)% for musical instruments [3]. Therefore, the timber’s drying
operation is mandatory before any woodworking process.
The presented paper is complementary with the study from [1] (by the same authors) and details the components
of the timber’s drying system, including the systems for heating, air evacuating and ventilation, command panel and
monitoring. Considering that the process of drying has large time constants and the drying regimes are included in
the command software, the proposed On-Off control method implemented using the Siemens programmable
controllers, combined with Step 7 software, proves its efficiency. The implemented interface allows the full control
of the operations, using pages of monitoring, recipes and graphics.
With adequate modifications, the schematic can be extended to the proportional-integrative-derivative (PID)
algorithm, including the control of the air moistening inside the drying chamber.

Acknowledgements

This paper is based upon work supported by the Energy and Electrotechnologies Management research center.

References

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