Grain Handling Control System Helps Frontier Cooperative Battle Labor Shortage
Customer Profile
- Full-service Coop that provides services in the areas of grain, agronomy, energy, and feed.
- Location of Project Plattsmouth, Nebraska
- Learn More about Frontier Cooperative
Project Overview
After combating labor shortages during peak season, Frontier Cooperative recognized a need for change. In collaboration with NorthWind, a plan was developed to upgrade the current manual panels with a fully automated system. The goal of this modernization was to eliminate outdated hardware and software while providing a grain handling control system that runs with minimal operator assistance.
The control solution developed to reach this goal involved replacing outdated and obsolete hardware with new componentry, adding hazardous monitoring equipment to increase safety at the facility, and new user-friendly PLC and HMI programs to reduce the crew size needed to run the storage equipment and assist with troubleshooting.
The NorthWind deliverables included programming for control and monitoring of 6 storage bins, 1 load out bin, 2 legs, 2 distributers, and 11 conveyors. Hardware deliverables include PLC, Remote IO, and 2 HMI Panels along with a computer for remote access and hazard monitoring equipment for the legs and conveyors.
Our Approach
To kick off the project, NorthWind’s team traveled to the Plattsmouth Nebraska location to conduct a design review. The team took account of all current hardware, software, and equipment being used to accurately provide electrical drawings.
The design team provided a new electrical drawing set that outlined the hardware, panel construction, IO distribution, and network connections. The existing push button panels that monitor bins and transfer equipment were replaced with a NorthWind PLC panel which houses the PLC and IO as well as power to feed two HMI panels. A new motor control center (MCC) was provided by the electrical installation contractor.
Key Technologies
- Ignition SCADA Graphics
- CompactLogix PLC and components
- AGI HazMon (hazard monitoring) equipment
NorthWind’s software automation team wrote the PLC & HMI programs to be intuitive and easy to use. A server was installed to host the HMI graphics that were built using Inductive Automation’s Ignition SCADA Software. This allows remote monitoring and control of the system from the site office enabling the crew to run and monitor the entire system from a conditioned space and with a reduced workforce.
The modernized system allows the Frontier operator to select which leg to use during material transfer and to select a source and destination. The operator presses enable on the HMIs to begin the transfer. The PLC communicates via ethernet with the legs’ distributors to position the distributors to the correct destination for material transfer. The equipment will use amp loads to know when the elevators and conveyors are loaded with material. This allows for automatic shut off if the equipment is empty for a configurable time.
A sixth bin was constructed and NorthWind provided a manually controlled panel for the discharge and loading of trucks from this bin, which is identical to the existing bins in this system.
The Impact
- The Grain Handling Control System allows the system to be operated with a smaller workforce. Allowing personnel to focus on other tasks and alleviates labor shortage issues during harvest.
- New operators quickly learn how to independently operate the system due to eliminating the reliance on tribal knowledge to successfully operate the system.
- The new automation system shows in real-time what equipment is running and it shows the destination of the material.
- The continuous hazard monitoring sensors on all the conveyors, drags and legs automatically shut down the equipment if running temperatures are unsafe.
- Other impacts of automation are still in progress. Frontier Cooperative can run the entire facility with one person if needed, and additional redundancy has been added. Frontier has had a successful 2024 harvest season using the new equipment and will continue to benefit from the efficiency and effectiveness of the automation system.
Learn more about NorthWind’s Solutions or reach out to schedule a walk through of a system.
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