【引言】
传统鸡粪烘干产线高度依赖老操作工经验，来料含水率一变、鸡毛垫料占比波动，就要现场反复试调。参数把控稍有偏差，就容易出现烘不干夹生、高温过烧有机质、负压失衡异味外溢等问题，必须专人长时间守在车间盯岗。金万泓卧式闪蒸智能 PLC 自控系统，把经验化操作转化成标准化自动控制，适配养殖场 24 小时不间断连续烘干，大幅降低人工依赖。
Traditional chicken manure drying lines rely heavily on the experience of veteran operators. Whenever the moisture content of incoming feedstock changes or the proportion of chicken feathers and bedding fluctuates, repeated on-site adjustments are required. Minor deviations in parameter control easily lead to under-dried raw material with wet cores, overheating and loss of organic matter, or negative pressure imbalance accompanied by odour leakage. Operators have to stay on-site for long hours to monitor the line.
Jinwanhong’s intelligent PLC automatic control system for horizontal flash dryers converts experience-based operation into standardised automatic control. It supports 24/7 non-stop continuous drying on farms and greatly reduces reliance on manual labour.
一、传统人工调节模式的痛点：靠经验生产，稳定性差
1.来料波动大：鲜鸡粪含水率忽高忽低、混有稻壳、秸秆、鸡毛，人工很难实时匹配工况；
2.参数滞后：人工定时取样测水分，发现出料不合格时，已经产出一大批次品料；
3.环保风险：负压调节全凭手感，负压偏低就容易臭气外溢，触发投诉；
4.劳动强度高：24 小时生产需要两班人员在岗值守，人工成本高，新手上手周期长；
5.安全隐患：堵料、超温、布袋压差超标等问题发现不及时，容易烧袋、闷机，甚至带来粉尘安全风险。
I. Pain Points of Traditional Manual Adjustment: Experience-driven Operation with Poor Stability
Unstable incoming material: Fresh chicken manure varies widely in moisture and is mixed with rice husks, straw and feathers, making real-time manual adjustment difficult.
Delayed parameter response: Operators take samples periodically to test moisture. By the time unqualified output is detected, a large batch of defective material has already been produced.
Environmental risks: Negative pressure is adjusted by intuition. Insufficient negative pressure often causes odour escape and public complaints.
Heavy labour intensity: Two shifts of staff are required for round-the-clock operation, pushing up labour costs, while new operators need a long training period.
Safety hazards: Blockages, over-temperature and excessive bag differential pressure may go unnoticed, which can result in burnt filter bags, machine stalling and even dust explosion risks.
二、金万泓卧式闪蒸智能控制系统硬件配置
整套自控单元围绕高湿鸡粪烘干工况定向配套，核心传感与执行单元包含：
✅ 出料端在线微波水分监测仪，实时读取干料含水率；
✅ 热风入口、腔体中段、尾气多点温度传感器；
✅ 腔体负压、除尘布袋压差变送器；
✅ 上料螺旋变频驱动、引风机变频模块、热源电动调节执行机构；
✅ PLC 主控单元触控操作屏；
✅ 物联网远程模块查看、报警推送；
✅ 声光报警、连锁保护输出端口。
所有传感器持续采集实时数据，形成闭环自动调节。
II. Hardware Configuration of Jinwanhong Horizontal Flash Intelligent Control System
The whole automatic control unit is customised for high-moisture chicken manure drying. Core sensors and actuators include:
✅ Online microwave moisture analyser at the discharge end for real-time moisture reading of finished material
✅ Multi-point temperature sensors at hot air inlet, mid-chamber and tail gas section
✅ Transmitters for chamber negative pressure and baghouse differential pressure
✅ Variable-frequency drives for feeding screw, induced draft fan and electric actuators for heat source regulation
✅ PLC main control unit with touchscreen HMI
✅ IoT remote module for data viewing and alarm push notifications
✅ Acoustic and visual alarm ports and interlock protection outputs
All sensors continuously collect real-time data to form a closed-loop automatic regulation system.
三、核心联动控制逻辑：水分为主变量，多设备协同自调
整套系统以目标出料含水率作为主控目标，预设好合格水分区间（有机肥发酵模式 25%-35%、燃料模式≤12%）：
·实测水分偏高（烘不干）：PLC 自动降低上料变频频率，减少进料量；同步微调热风温度、提升引风机转速，延长物料停留与换热时间；
·实测水分偏低（过干、浪费燃料）：适度提升进料速度，下调热风负荷，避免有机质高温碳化，节约燃料；
·负压偏离设定区间：自动调节引风机频率，稳定腔体负压，保证全程密闭不外溢臭气粉尘；
·热风温度偏离阈值：联动热源调节机构，稳定烘干温度曲线，规避局部高温糊料。不需要人工实时旋钮调节，系统动态跟随来料变化自适应。
III. Core Linked Control Logic: Moisture as the Primary Variable for Coordinated Automatic Adjustment of Multiple Devices
The system targets the preset outlet moisture range: 25%–35% for organic fertiliser fermentation, and ≤12% for biomass fuel production.
When measured moisture is too high (under-dried): The PLC automatically reduces the feeding frequency to cut feed rate, slightly raises hot air temperature and increases the induced draft fan speed to extend material residence time and heat exchange.
When measured moisture is too low (over-dried and fuel-wasting): The feed speed is moderately increased while heat load is reduced to avoid carbonisation of organic matter and save fuel.
When negative pressure drifts outside the set range: The induced draft fan frequency is adjusted automatically to stabilise chamber negative pressure and prevent odour and dust leakage under sealed operation.
When hot air temperature exceeds thresholds: The heat source actuator is interlocked to stabilise the drying temperature curve and eliminate local overheating and material pasting.
No constant manual knob adjustment is needed; the system adapts dynamically to variations in incoming material.
四、多层安全预警与连锁保护机制，避免故障扩大
针对鸡粪烘干高温、含粉尘、高粘性工况，设置分级报警 + 连锁停机逻辑：
1.超温保护：热风、腔体温度超过上限，声光报警；持续升温自动切断热源，补入冷风降温，防止物料焦化、布袋烧毁；
2.堵料保护：主轴电流、进料负荷持续超标，判定堵料，先报警提示；达到阈值自动停止上料，防止闷机；
3.负压异常保护：负压过低（有漏气、异味外溢风险）立即报警，提醒人员检查密封、软连接；负压过高同步检查风道堵塞；
4.除尘压差超标：布袋堵塞、清灰失效预警，避免阻力过大造成整条产线风量失衡；
IV. Multi-layer Safety Warning and Interlock Protection Mechanism to Prevent Fault Escalation
Hierarchical alarm and interlock shutdown logic are designed for high-temperature, dust-laden and sticky chicken manure drying conditions:
Over-temperature protection: Acoustic and visual alarms trigger when hot air or chamber temperature exceeds the upper limit. If temperature keeps rising, the heat source is cut off automatically and cold air is introduced to cool down, preventing material coking and bag burnout.
Blockage protection: If spindle current and feeding load stay above the limit, a blockage is identified. An alarm is triggered first; feeding stops automatically once the threshold is hit to avoid machine stalling.
Abnormal negative pressure protection: A low negative pressure alarm alerts operators to check seals and flexible connections for leakage risks. High negative pressure triggers inspection for blocked air ducts.
Excessive dust bag differential pressure alarm: Warns of clogged bags or failed ash cleaning, preventing airflow imbalance across the whole line caused by excessive resistance.
五、智能控制系不用死守车间
触摸屏：集中展示实时水分、多点温度、负压、电流、风机频率，支持直接设置目标水分、各参数上下限；可切换手动 / 自动模式，检修调试时切手动；
不是远程随便启停设备，重点是异常第一时间知晓，值班人员不用一直在车间蹲守，定时巡检即可。系统自动存储历史曲线、产量、能耗记录，方便核算每吨烘干能耗、生产台账。
V. Intelligent Control Frees Operators from Continuous Workshop Presence
The touchscreen displays real-time moisture, multi-point temperature, negative pressure, current and fan frequency. Operators can set target moisture and parameter upper/lower limits, and switch between automatic and manual modes for maintenance and commissioning.
The system is not designed for unrestricted remote start-stop. Its main value is instant abnormal alerts, so staff do not need to stay in the workshop continuously and only perform periodic inspections. Historical curves, output and energy consumption records are stored automatically to support energy accounting and production log management.
六、不同热源对应的自控逻辑差异
·生物质热源：重点联动炉排进料、配风、引风，稳定炉膛温度；升温惯性大，PID 调节偏平缓，避免温度骤升骤降；重点监测炉膛与尾气温度，防止火星带入主机；
·天然气热源：响应速度快，燃气阀可快速微调，控温精度更高；适合对出料品质要求严格、需要频繁调整工况的项目，安全联锁增加燃气检漏联动。
VI. Differences in Automatic Control Logic for Various Heat Sources
Biomass heat source: Focuses on coordinated control of grate feeding, air distribution and induced draft to stabilise furnace temperature. Due to high thermal inertia, PID regulation is gentle to avoid sharp temperature fluctuations. Furnace and tail gas temperatures are closely monitored to stop sparks from entering the main dryer.
Natural gas heat source: Fast response enables fine adjustment of gas valves for higher temperature control precision. Suitable for projects demanding strict product quality and frequent working condition changes. Additional gas leakage interlock protection is integrated for safety.
七、人员配置变化：从专人盯岗，转向巡检值守
普通基础款产线：24 小时连续生产，每班至少 1 人紧盯参数、取样调机，依赖熟练操作工；
PLC 智能自控款：系统自动稳参数，岗位转为定时巡检制。一条卧式闪蒸烘干产线，仅安排巡检人员，定时查看设备异响、润滑、物料来料情况；夜间值班人员可在值班室待命，收到报警通知到场处置，大幅降低用工压力，新人上手门槛更低。
VII. Changes in Staffing: From Full-time Monitoring to Routine Inspection
Basic conventional line: For 24-hour continuous operation, at least one operator per shift must monitor parameters and sample test material, relying heavily on experienced workers. PLC intelligent control line: Parameters are stabilised automatically. The role shifts to periodic inspection. Only patrol staff are required to check for abnormal noise, lubrication and incoming material conditions. Night-duty staff can wait in the control room and respond only when alarms arrive, greatly lowering labour pressure and the learning barrier for new recruits.
结语
如果你正在规划鸡粪烘干产线，想要配套智能自控方案、远程监控，我们可以根据你的热源类型、目标出料水分，定制 PLC 控制逻辑、触摸屏画面，同步规划自动化配套方案。
If you are planning a chicken manure drying line and wish to equip it with intelligent automatic control and remote monitoring, we can customise PLC control logic and touchscreen interfaces according to your heat source type and target outlet moisture, together with a complete automation supporting scheme.