A compost full-process automatic control system

Abstract

The application relates to a full-process automatic control system for composting, which comprises a sensing unit for collecting composting process parameters in real time, the sensing unit comprising a temperature / O2 probe and a gas detection module. The temperature / O2 probe is installed in the interior of a composting body, and the gas detection module is fixed to the top of a fermentation bin; a control unit adopts a PLC controller; an execution unit comprises a variable-frequency fan, a turning machine and a screw conveyor, the variable-frequency fan is installed at an air inlet on the side of the fermentation bin, the turning machine is arranged in the fermentation bin, and the screw conveyor is installed at a discharge port at the bottom of the fermentation bin; the control unit further comprises a relay unit, the PLC controller is connected with the sensing unit, and an output end is electrically connected with the execution unit; the temperature / O2 probe and the gas detection module are electrically connected with an input port of the PLC controller, and the variable-frequency fan, the turning machine and the screw conveyor are respectively electrically connected with output ports of the relay unit and the PLC controller. The application has the effect of improving the automation level in the composting production process.

Description

Technical Field

[0001] This application relates to the field of organic waste treatment technology, and in particular to an automated control system for the entire composting process. Background Technology

[0002] In the field of organic waste resource utilization, composting technology achieves waste reduction and nutrient recovery through microbial degradation, and is one of the key technologies in agriculture and environmental protection. With the increasing demand for large-scale organic waste treatment, traditional composting systems rely on manual experience to control core process parameters such as ventilation and turning, which is difficult to meet the requirements of efficient and stable industrial production. There is an urgent need to improve the precision of process control and the reliability of the system through automated control technology.

[0003] Existing composting control systems suffer from several major drawbacks: insufficient monitoring and control efficiency. Traditional systems employ single-point temperature or oxygen concentration detection, failing to cover environmental differences at different depths and in different areas of the compost pile. This leads to blind spots, causing delays or over-implementation of ventilation and turning strategies, resulting in low fermentation efficiency (extending the cycle by 20%-30%) and energy waste (up to 30% of fans are ineffective). Equipment linkage control relies on manual intervention and lacks real-time closed-loop control logic that integrates multiple parameters, making it difficult to adapt to the dynamically changing environmental demands during composting. System reliability and stability are also problematic. The single PLC control architecture presents a single point of failure risk; a main controller failure can easily paralyze the entire system, severely impacting production continuity. Furthermore, the lack of an emergency power supply module means that monitoring and execution equipment may shut down during power outages, potentially triggering anaerobic fermentation and sudden temperature changes, increasing the risk of secondary pollution from waste disposal. Insufficient environmental adaptability and flexibility: There is a lack of flexible configuration schemes for monitoring characteristic gases (such as NH3 and H2S) of different raw materials such as livestock and poultry manure and garden greening waste. The composting cycle of the pile is significantly extended in the low temperature environment in winter (more than twice the conventional cycle). The existing system does not integrate an effective temperature and humidity coordinated control mechanism, making it difficult to cope with complex climatic conditions and diverse raw material characteristics.

[0004] The aforementioned problems result in traditional composting systems having pain points such as low fermentation efficiency, high energy consumption, high failure risk, and poor raw material adaptability. There is an urgent need to build a fully automated control system through distributed sensing, intelligent control, redundant design, and multi-parameter linkage technology to achieve precise control and stable operation of the composting process. Utility Model Content

[0005] To improve the level of automation in the composting production process, this application provides an automated control system for the entire composting process.

[0006] The automated control system for the entire composting process provided in this application adopts the following technical solution: An automated control system for the entire composting process, comprising: A sensing unit is used to collect composting process parameters in real time. The sensing unit includes a temperature / O2 probe and a gas detection module. The temperature / O2 probe is installed inside the compost pile, and the gas detection module is fixed to the top of the fermentation chamber. The control unit employs a PLC controller, and the input terminals of the PLC controller are connected to... The sensing unit is connected; The execution unit includes a variable frequency fan, a turning machine, and a screw conveyor, wherein the variable frequency fan... The turning machine is installed at the air inlet on the side of the fermentation chamber, and the screw conveyor is installed at the discharge port at the bottom of the fermentation chamber. The control unit further includes a relay unit. The input terminal of the PLC controller is connected to the sensing unit via a signal line, and the output terminal is electrically connected to the execution unit via the relay unit. The temperature / O2 probe and the gas detection module are electrically connected to the input port of the PLC controller via independent signal lines, and the variable frequency fan, the turning machine and the screw conveyor are electrically connected to the output port of the PLC controller via the relay unit. The emergency power supply module includes a battery, an inverter, and a charging controller. The output of the inverter is electrically connected to the PLC controller, the sensing unit, and the execution unit through the relay unit.

[0007] By adopting the above technical solution and constructing a collaborative architecture of sensing units, control units, execution units, and emergency power supply modules, real-time acquisition and closed-loop control of composting process parameters are achieved. The distributed deployment of sensing units (such as internal temperature / O2 probes and silo top gas detection modules) helps acquire multi-dimensional environmental data, providing a basis for the control unit's decision-making. The control unit drives the execution units through relay units, achieving automated responses to operations such as ventilation, turning, and discharging, reducing manual intervention. The addition of the emergency power supply module ensures that the overall system can maintain normal operation for a short period during power grid failures, providing time for operators to perform maintenance and improving overall operational stability.

[0008] Preferably, the temperature / O2 probe includes a PT100 platinum resistance temperature sensor and an electrochemical O2 sensor, and the gas detection module integrates an NH3 sensor and an H2S sensor; or, the gas detection module adopts an infrared spectroscopic gas analyzer, and the gas detection module is electrically connected to the PLC controller.

[0009] By adopting the above technical solutions, the temperature / O2 probe uses a combination of PT100 platinum resistance thermometer and electrochemical sensor, which takes into account both high-precision temperature measurement and rapid oxygen concentration response characteristics, and is suitable for the complex environment of high temperature and high humidity during composting. The gas detection module provides optional configurations of NH3 and H2S sensors or infrared spectrometers to meet the characteristic gas monitoring needs of different composting raw materials (such as livestock and poultry manure and garden waste), and enhance the applicability of the system.

[0010] Preferably, the temperature / O2 probes are evenly distributed inside the compost in a 2m×2m grid, the gas detection module is located on the silo, and the gas detection module is 1.5m away from the compost.

[0011] By adopting the above technical solution, the temperature / O2 probes are evenly distributed in a 2m×2m grid, covering different depths and areas of the compost pile, reducing blind spots and ensuring the representativeness of the collected data. The gas detection module is set 1.5m away from the compost surface to balance the relationship between gas diffusion delay and detection sensitivity, avoiding dust contamination of the sensor due to being too close or response lag due to being too far away. This provides the control unit with more accurate environmental parameters, supports the formulation of refined ventilation and turning strategies, and thus optimizes fermentation efficiency.

[0012] Preferably, the PLC controller includes a control board and an interface board. The control board integrates a central processing unit, a motion controller, and an I / O controller. The interface board is provided with an EtherCAT bus interface and a gLink bus interface. The relay unit is connected to the PLC controller through the EtherCAT bus interface.

[0013] By adopting the above technical solutions, the PLC controller integrates an EtherCAT bus interface, enabling high-speed data communication with the relay unit, reducing signal transmission delay, and improving system response speed. The gLink bus interface configuration is compatible with existing industrial equipment communication protocols, facilitating integration with other production line modules (such as weighing systems and transport machinery) and enhancing system scalability. The modular design of the control board and interface board simplifies hardware maintenance procedures, allowing for quick replacement of faulty functional modules and reducing downtime.

[0014] Preferably, the variable frequency fan is formed by connecting several constant speed fans in parallel, and the several constant speed fans are electrically connected to the PLC controller through the relay unit.

[0015] By adopting the above technical solution, the variable frequency fan consists of multiple constant speed fans connected in parallel. It can achieve stepped airflow adjustment through start-stop combinations. Compared to a single variable frequency fan, some fans can be shut down during low-load operation to reduce energy consumption; at the same time, the reliability of the constant speed fans is maintained, avoiding the risk of failure that may occur during long-term operation of the variable frequency device. This design can ensure ventilation while also considering energy saving and stability requirements, and is particularly suitable for composting stages that require frequent airflow adjustments (such as the heating and maturation periods).

[0016] Preferably, it also includes a temperature and humidity sensor and a heating device. The temperature and humidity sensor is installed inside the composting chamber, and the heating device is located at the bottom of the fermentation chamber. The humidity sensor and the heating device are connected to the PLC controller through the relay unit.

[0017] By adopting the above technical solutions and introducing temperature and humidity sensors and heating devices, a more comprehensive environmental control system is constructed: the temperature and humidity sensors monitor changes in humidity inside the compost pile in real time, and the heating devices maintain a suitable temperature by heating the bottom of the fermentation chamber, solving the problem of fermentation stagnation caused by low temperatures in winter and shortening the composting cycle. The linkage control of the humidity sensor and the heating device enables dynamic adjustment of the moisture content of the compost pile, avoiding anaerobic fermentation caused by excessive humidity or inhibition of microbial activity by excessively low humidity.

[0018] Preferably, the emergency power supply module further includes a solar panel, which is electrically connected to the PLC controller and the battery.

[0019] By adopting the above technical solution, the combination of solar panels and batteries provides supplementary energy for emergency power supply modules, reducing dependence on mains power. This can reduce system operating costs, especially in areas with abundant sunshine, achieving energy self-sufficiency and enhancing system independence.

[0020] Preferably, the control unit adopts a dual PLC redundant control architecture, including a main PLC controller and a backup PLC controller, which are connected to the execution unit through a relay unit.

[0021] By adopting the above technical solutions, the dual PLC redundancy architecture achieves seamless switching when the main PLC fails through the synchronous operation of the main and backup controllers, ensuring the continuity of control commands, reducing the risk of system paralysis caused by single point of failure, potentially avoiding signal interference during redundancy switching, ensuring the accuracy of the execution unit's actions, meeting the high reliability requirements of composting production, and is especially suitable for large-scale production lines, reducing economic losses caused by downtime.

[0022] In summary, this application includes at least one of the following beneficial technical effects: 1. Real-time acquisition of internal environmental data through distributed sensing units (temperature / O2 probes + gas detection modules), combined with the closed-loop control logic of the PLC controller, enables dynamic response of execution units such as ventilation and turning. This multi-parameter collaborative monitoring method, compared to traditional single-point detection, reduces monitoring blind spots, improves the precise control of the composting process, and helps shorten the fermentation cycle. 2. The PLC controller's EtherCAT bus interface supports high-speed data transmission and is compatible with existing industrial equipment communication protocols. The modular design of the relay unit facilitates maintenance and upgrades. The optional configuration of the gas detection module can be flexibly adjusted according to different composting raw materials, shortening the deployment cycle and providing technical support for large-scale composting production lines. 3. The combination of solar panels and batteries provides supplementary energy for emergency power supply modules, reduces dependence on mains power, achieves energy self-sufficiency, and enhances the system's independence. Attached Figure Description

[0023] Figure 1 This is an overall system principle block diagram of a fully automated composting control system according to an embodiment of this application.

[0024] Figure 2 This is a system principle block diagram of various electrical components in a fully automated composting control system according to an embodiment of this application.

[0025] Figure 3 This is a schematic diagram of the interface displayed on the control panel when the fully automated composting control system of this application is not in operation.

[0026] Figure 4 This is a schematic diagram illustrating an example of the interface displayed on the control panel during operation of an automated composting control system according to an embodiment of this application.

[0027] Explanation of reference numerals in the attached diagram: 1. Sensing unit; 11. Temperature / O2 probe; 12. Gas detection module; 13. Temperature and humidity sensor; 2. Control unit; 21. PLC controller; 211. Control board; 212. Interface board; 22. Relay unit; 23. Main PLC controller; 24. Backup PLC controller; 3. Execution unit; 31. Variable frequency fan; 32. Compost turner; 33. Screw conveyor; 34. Heating device; 4. Emergency power supply module; 41. Battery; 42. Inverter; 43. Charging controller; 44. Solar panel. Detailed Implementation

[0028] The following is in conjunction with the appendix Figure 1-4 This application will be described in further detail.

[0029] Reference Figure 1 and Figure 2This application discloses a fully automated composting control system. The overall architecture consists of a sensing unit 1, a control unit 2, an execution unit 3, and an emergency power supply module 4 connected in series via signal and power lines. The control unit 2 also includes a relay unit 22. The sensing unit 1 includes a temperature / O2 (oxygen) probe 11 and a gas detection module 12. The temperature / O2 (oxygen) probe 11 and the gas detection module 12 are distributed to cover the interior of the compost pile and the top of the fermentation chamber, respectively. Real-time collected data is transmitted to the PLC controller 21 of the control unit 2 via independent signal lines. After logic processing, the relay unit 22 drives the execution unit 3, forming a closed-loop control link of "data acquisition - command processing - equipment control".

[0030] Specifically, in combination Figure 2 As shown, the temperature / O2 probe 11 integrates a PT100 platinum resistance temperature sensor and an electrochemical O2 sensor, evenly distributed in a 2m×2m grid inside the compost pile, covering different depths of 0.5m, 1.5m, and 2.5m to ensure the acquisition of temperature and oxygen concentration gradient data between the center and edge of the compost pile. The gas detection module 12 is fixed to the top of the fermentation chamber, 1.5m from the compost surface. Depending on the type of compost material, it can integrate NH3 (ammonia), H2S (hydrogen sulfide) sensors (suitable for livestock manure) or an infrared spectral gas analyzer (suitable for mixed organic waste), monitoring the concentration of volatile gases in real time and electrically connecting to the input port of the PLC controller 21 via an independent signal line. The temperature and humidity sensor 13, synchronously deployed inside the compost pile, works in conjunction with the temperature / O2 probe 11 to provide the control unit 2 with real-time data on the moisture content of the compost pile and the ambient humidity.

[0031] Furthermore, the control unit 2 adopts a dual-redundant control architecture, including a main PLC controller 23 and a backup PLC controller 24, which communicate at high speed with the relay unit 22 via an EtherCAT bus interface. The PLC controller 21 integrates a control board 211 and an interface board 212: the control board 211 has a built-in central processing unit, motion controller, and I / O controller, enabling multi-parameter fusion calculation and equipment linkage control; the interface board 212 is equipped with an EtherCAT bus interface and a gLink bus interface. The EtherCAT bus interface is used for high-speed data interaction with the relay unit 22, while the gLink bus interface is compatible with existing industrial equipment communication protocols and supports integration with external weighing systems, transportation machinery, and other modules, enhancing system scalability. When the temperature / O2 probe 11 detects an oxygen concentration below 18% or a temperature above 65°C, the control board 211 generates a ventilation command, which controls the variable frequency fan 31, composed of three constant-speed fans connected in parallel, via the relay unit 22. Through start-stop combinations, a ventilation range of 500-1500m² is achieved. 3The air volume is adjusted in a stepped manner at a rate of / h. If the oxygen concentration in the same grid area remains below 15% and the temperature difference exceeds 10℃, the turning machine 32 (which typically consists of a frame, drive system, turning device, walking mechanism, etc., and is an existing compost turning device; its specific composition and working principle will not be elaborated here) is triggered to turn the compost pile to a depth of 0.8-1.2m through a gear and rack transmission device, thereby balancing the temperature and permeability of the pile.

[0032] It should be noted here that both the main PLC controller 23 and the backup PLC controller 24 are PLCs (Programmable Logic Controllers), which include multiple functions such as logic control, timing control, analog control, and multi-machine communication. They also have human-machine interfaces to facilitate the control and adjustment of the PLC. They are existing controllers and will not be distinguished here. Their specific composition and working principle will not be described in detail here.

[0033] Meanwhile, each device in execution unit 3 is electrically connected to PLC controller 21 via relay unit 22: execution unit 3 includes variable frequency fan 31, compost turner 32, and screw conveyor 33. Compost turner 31 can be a hydraulic compost turner. Variable frequency fan 31 is installed at the air inlet 51 on the side of fermentation chamber. Compost turner 32 reciprocates along the track of fermentation chamber, and the turning frequency can be adjusted according to control commands (0.5-2 times / day). Screw conveyor 33 is installed at the discharge port 52 at the bottom of fermentation chamber, equipped with a speed sensor to provide real-time feedback on the discharge rate and perform closed-loop adjustment to avoid material blockage or idling. Heating device 34 (composed of resistance heating wire, power adjustable from 5-15kW) is installed at the bottom of fermentation chamber. When temperature and humidity sensor 13 detects that the temperature of the compost pile is below 20℃ and the humidity is above 75%, it is driven by PLC controller 21 to maintain the temperature inside the chamber at 25-30℃.

[0034] It should be noted that the relay unit 22 consists of several relays, which are used to realize the electrical connection and signal transmission between the sensing unit 1, the control unit 2, the execution unit 3 and the emergency power supply module 4. The individual relays will not be described here.

[0035] Reference Figure 1 and Figure 2The emergency power supply module 4 integrates a solar panel 44, a battery 41 (capacity 100Ah), a charging controller 43, and an inverter 42 (output 220V AC). The solar panel 44 is installed at a 30° angle on the top of the fermentation chamber and is electrically connected to the charging controller 43 and the battery 41. Under normal operating conditions, the charging controller 43 converts solar power or mains power into DC power and stores it in the battery 41. When the mains power is interrupted, the inverter 42 automatically switches to the battery 41 power supply mode and maintains the operation of the PLC controller 21, the sensing unit 1, and the key execution units (variable frequency fan 31 and compost turner 32) for at least 2 hours through the relay unit 22, thus buying time for manual intervention.

[0036] In the embodiments of this application, reference is made to Figure 3 and Figure 4 The various units work together in the following ways: Sensing unit 1 uploads parameters such as temperature, O2 concentration, NH3 / H2S concentration, and humidity to PLC controller 21 in real time to form a data matrix. Control board 211 generates control commands through preset algorithms (such as PID control) and transmits them to relay unit 22 via EtherCAT bus and gLink bus to drive execution unit 3 to perform precise actions. The dual-redundant PLC controller architecture ensures that the main and backup controllers operate synchronously and seamlessly switch when the main PLC controller 23 fails, avoiding single point of failure. Emergency power supply module 4 achieves energy redundancy by combining solar energy and batteries, improving system reliability.

[0037] It should also be noted that, in this embodiment, for ease of explanation, the sensing unit 1 and the execution unit 3 are described by mounting them on the fermentation chamber. In other embodiments, the above components can also be mounted in composting workshops or other scenarios used for composting production. Since they perform the same function, their installation location in composting workshops or other similar locations will not be described here.

[0038] The implementation principle of the fully automated composting control system in this application embodiment is as follows: This application constructs a fully automated control system by using multi-dimensional data acquisition of distributed sensing units (temperature / O2 probe grid layout, precise positioning of gas detection modules), high-speed logic operation of dual redundant PLC controllers (support for EtherCAT and gLink bus interfaces), precise action coordination of execution units (parallel frequency conversion of fixed-speed fans, linkage control of heating devices), and solar-battery redundancy design of emergency power supply modules. This system enables precise regulation and reliable operation of the composting process, meeting the engineering requirements of large-scale organic waste treatment.

[0039] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A composting full-process automation control system, characterized in that, include: The sensing unit (1) is used to collect composting process parameters in real time. The sensing unit (1) includes a temperature / O2 probe (11) and a gas detection module (12). The temperature / O2 probe (11) is installed inside the composting body, and the gas detection module (12) is fixed to the top of the fermentation chamber. The control unit (2) adopts a PLC controller (21), and the input terminal of the PLC controller (21) is connected to the sensing unit (1) through a signal line; The execution unit (3) includes a variable frequency fan (31), a turning machine (32) and a screw conveyor (33). The variable frequency fan (31) is installed at the air inlet on the side of the fermentation chamber, the turning machine (32) is set inside the fermentation chamber, and the screw conveyor (33) is installed at the discharge port at the bottom of the fermentation chamber. The control unit (2) further includes a relay unit (22). The input terminal of the PLC controller (21) is connected to the sensing unit (1) via a signal line, and the output terminal is electrically connected to the execution unit (3) via the relay unit (22). The temperature / O2 probe (11) and the gas detection module (12) are electrically connected to the input port of the PLC controller (21) through independent signal lines, and the variable frequency fan (31), the turner (32) and the screw conveyor (33) are electrically connected to the output port of the PLC controller (21) through the relay unit (22). The emergency power supply module (4) includes a battery (41), an inverter (42) and a charging controller (43). The output terminal of the inverter (42) is electrically connected to the PLC controller (21), the sensing unit (1) and the execution unit (3) through the relay unit (22).

2. The full-process composting automation control system according to claim 1, characterized in that: The temperature / O2 probe (11) includes a PT100 platinum resistance temperature sensor and an electrochemical O2 sensor. The gas detection module (12) integrates an NH3 sensor and an H2S sensor. Alternatively, the gas detection module (12) adopts an infrared spectrometer gas analyzer. The gas detection module (12) is electrically connected to the PLC controller (21).

3. The full-process composting automation control system according to claim 2, characterized in that: The temperature / O2 probe (11) is evenly distributed inside the compost in a 2m×2m grid, and the gas detection module (12) is located on the fermentation chamber and is 1.5m away from the compost.

4. The full-process composting automation control system according to claim 1, wherein: The PLC controller (21) includes a control board (211) and an interface board (212). The control board (211) integrates a central processing unit, a motion controller, and an I / O controller. The interface board (212) is provided with an EtherCAT bus interface and a gLink bus interface. The relay unit (22) is connected to the PLC controller (21) through the EtherCAT bus interface.

5. The full-process composting automation control system according to claim 1, wherein: The variable frequency fan (31) is formed by connecting several constant speed fans in parallel, and the several constant speed fans are electrically connected to the PLC controller (21) through the relay unit (22).

6. The full-process composting automation control system of claim 1, wherein: It also includes a temperature and humidity sensor (13) and a heating device (34). The temperature and humidity sensor (13) is installed inside the compost, and the heating device (34) is located at the bottom of the fermentation chamber. The humidity sensor (13) and the heating device (34) are connected to the PLC controller (21) through the relay unit (22).

7. The full-process composting automation control system of claim 1, wherein: The emergency power supply module (4) also includes a solar panel (44), which is electrically connected to the PLC controller (21) and the battery (41).

8. The full-process composting automation control system of claim 1, wherein: The control unit (2) adopts a dual PLC redundant control architecture, including a main PLC controller (23) and a backup PLC controller (24). The main PLC controller (23) and the backup PLC controller (24) are connected to the execution unit (3) through a relay unit (22).

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