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bakenet

Key Points

  • Rapid Installation

  • Minimum production downtime required to fit

  • Proven Software works out of box

  • Advanced diagnostics available to aid trouble shooting

  • Easy to repair using hot swap technology

  • Energy efficiency justifies ROI (return on investment)

  • Software developed with bakery partnerships increases quality and productivity

  • After care service using AGRA (Air/Gas Ratio Analyzer) results in near “perfect combustion”

  • Open source architecture, no proprietary components

  • Widespread support and availability

  • Proven technology

 

The DSI systems (Direct Spark Ignition) on industrial ovens have grown and evolved over the years to become key to the quality, efficiency and control of the today’s baking process. Oven operating systems being offered today claim energy efficient, product-enhancing features with simple user interfaces. How many systems can actually live up to this claim?

More and more bakeries are turning to our innovative approach in dealing with age old problems. Combining a new approach with in-depth process knowledge, BakeNet™ provides a complete solution for new ovens, upgrades or modification to existing systems. Absolute, minimal downtime for installation does not even begin to compromise the cutting edge control buried deep within a simplistic, operator friendly, baking solution. BakeNet™ provides features which to date have been unavailable; blown fuse or module failure detection, manual override indication, failed flame count and duration as well as the standard flame failure detection. Our approach does not even end at installation.

Using the Air/Gas Ratio Analyzer (AGRA) we can take your ovens to an efficiency quite simply, unmatched within the industry. For a standard, constant ignition oven, we can usually achieve an annual saving of up to 25% in gas consumption and on a “new” system we can often improve efficiency between 4-6% over and above anything obtained before. Being unique in the industry, we offer services to take your oven closer to “perfect combustion” and lower energy usage. The energy savings alone, should, in nearly all cases provide the return on investment needed to justify the cost of upgrading your oven.

Together with the energy saving technology is our process knowledge. Proven in leading bakeries, our software provides unrivaled active product tracking reducing changeover times to a minimum. Gap Control eliminates flash heat between changeovers and natural product gaps by reacting before a load change is normally detected. Recipe control, progressive cutback, enhanced, cascading PID control, batch reporting are some of the features that are establishing Flynn as the industry leaders in providing the only, currently available complete baking solution.

What is BakeNet™?

Def.- a machine area network designed specifically for industrial baking ovens

BakeNet™ was first conceived in 2005 and has since been developed into a complete baking solution. It comprises of a proven industrial, open source network and machine mountable IO. It was originally aimed at replacing a DSI system rapidly, thus reducing production downtime to an absolute minimum and allowing replacement of a complete system within the normal production constraints of a modern day bakery. Enhancements now provide benefits on maintenance, production and corporate levels while remaining cost effective. Together with BakeNet™ is the operating software which provides quality improvement and return on investment by actually saving on annual gas consumption yet delivering improved product quality.
BakeNet™ Components

The network

The backbone of BakeNet™ is an industrial network called “DeviceNet”. DeviceNet is a simple, robust open industrial control network system that was first established by Allen-Bradley and layered on top of CAN (Controller Area Network, developed by Bosch) It is a world leading communication protocol used in the automation industry to interconnect control devices for data exchange. Typical applications include information exchange, safety devices, and large I/O control networks. In order to promote the use of DeviceNet worldwide, Rockwell Automation (parent company of Allen Bradley) has adopted the "open" concept and decided to share the technology to third party vendors. Hence, it is now managed by the Open DeviceNet Vendors Association (ODVA http://www.odve.org ), an independent organization located in North America. ODVA maintains specifications of DeviceNet and oversees advances to DeviceNet. In addition, ODVA ensures compliance to DeviceNet standards by providing conformance testing and vendor conformity
The main advantages of this networking solution are that it reduces the cost and time to wire and install industrial devices, while providing interchangeability of "like" components for multiple vendors. There is a good balance between cost, practicality and noise immunity.
It scores above many other field networks in that it is simple to maintain, runs the power for the devices within the communication cable and is particularly noise immune. Because it is so popular and open, devices are readily available worldwide and support is widespread.
DeviceNet is also widely used in modern bakeries today. For nearly 10 years, it has been used by most OEM’s to connect remote IO, Flex IO and compact IO on bakery systems throughout the World. Because it is so stable, most people do not even know they have it in place.

The I/O – inputs and outputs

The main components of BakeNet™are the ZoneLink, BurnerLink, PurgeLink1 and BurnerSentry.

ZoneLink

The ZoneLink sits on the network and controls as the name suggests, a zone. This typically consists of multiple thermocouples, modulating valves and pressure transducers. Each ZoneLink can be individually configurable to meet even the most demanding zone. Each channel is independently replaceable so should a module fail, only that module will need to be replaced. Cost of ownership is therefore kept to a minimum. The unit itself is connected via Quick-Disconnect plugs and sockets. There is no wiring to connect. Simply screw in the cable and it is ready to go. Each analog channel is independent and has a unique identifying fingerprint so the wrong cable cannot be connected accidentally. Each ZoneLink is PnP (plug and play) it is enabled for hot-swap. Hot swapping or hot plugging is the ability to remove and replace components of a machine, while it is operating without needing to turn off or reset it. Simply set the address and plug it in. This reduces the MTR (mean time to repair) and makes troubleshooting a breeze.
There is also ample room on the network to accommodate even the largest, multi-zone, burner intensive oven out there today.

BurnerLink

The BurnerLink interfaces to 8 burner ignition/flame controllers, called BurnerSentries. Typically, two of these units will feed a zone of 16 burners. Any combination can be readily accommodated. Again the unit is hot-swap and has a further option to enable the burner controllers if the network should go down. Simply remove the cover and select “network override” to enable the burner controllers to continue operation. Each cannel is independently fused for protection. The BurnerLink not only controls the burner controller but also monitors it for operation providing both visual indication and alarming on the HMI.
It can differentiate between a failed controller and failed flame thus saving a lot of time troubleshooting failed burners.
It will also indicate that a burner has been left in “network override” mode providing an unsurpassed level of information and taking the guesswork out of troubleshooting altogether. Each connection is made via a Quick-Disconnect so no physical wiring is necessary.

Burner Sentry

The Burner Sentry itself is based on the reliable S87 Honeywell controller. Flame rectification continuity is ensured with the ground path integral to the solenoid cable, again it is Quick-Disconnect. This eliminates the ground wiring between the burner faceplate and the BurnerSentry. A local on/off switch is provided for maintenance as is local power on and flame failure indication.