Hohes Risiko von Fehlern bei traditioneller Stichprobenprüfung, Online-Nahinfrarot-Feuchtigkeitsmessgerät mit Vollbreitenüberwachung – AMT/SFY-HW

Hohes Risiko von Fehlern bei traditioneller Stichprobenprüfung, Online-Nahinfrarot-Feuchtigkeitsmessgerät mit Vollbreitenüberwachung

1. Solution overview

Online near-infrared (NIR) Moisture monitoring system, relying on the selective absorption characteristics of water molecules for specific near-infrared bands, using non-contact, non-destructive continuous detection, real-time collection of moisture content of production line materials, data connected to PLC、central control system, realizing online moisture monitoring, over-limit alarms, and closed-loop regulation of drying process. Replacing traditional manual sampling + Oven testing, solving pain points such as testing lag, missed sampling inspection, and large manual errors, suitable for belt conveying, chutes, screws, pipelines, silos and other continuous solid material production lines, helping production quality improvement, energy saving and consumption reduction, and traceable quality data Douyin Baike.

2. Measurement principle

The near-infrared light source emits infrared light of a specific wavelength to illuminate the material, and water molecules absorb near-infrared light in a specific band; the detector receives the spectral signal diffusely reflected back from the material, and through the built-in spectral algorithm and temperature compensation model, deducts the interference of material color, particle size, and ambient temperature, and converts the material moisture content in real time.

Features: non-contact, no damage to materials, millisecond-level output, no need for sampling and sample preparation, continuous uninterrupted measurement.

Hohes Risiko von Fehlern bei traditioneller Stichprobenprüfung, Online-Nahinfrarot-Feuchtigkeitsmessgerät mit Vollbreitenüberwachung

3. System composition

The entire online near-infrared moisture monitoring system consists of hardware + The software consists of two major parts:

Near-infrared detection probe: built-in light source, optical filter components, photodetector, temperature sensor;IP65 Industrial dustproof and waterproof housing; optional purging dustproof device, suitable for high-dust working conditions; split design, probe and controller separated, high-temperature site can be remotely installed.

Controller host: touch screen display, real-time display of moisture and temperature; built-in material model library, supports multi-recipe switching; local storage of historical data.

Signal communication module: standard 4-20mA Analog,RS485 Modbus；optional Profinet、TCP/IP Ethernet, connected to DCS/PLC/ Upper computer.

Supporting installation components: mounting bracket, adjustable base, light shield, air purging component, cables.

Upper computer software (optional): data storage, report export, trend curves, alarm records, remote viewing, meeting factory audit quality traceability requirements.

4. Typical installation application scenarios

Belt conveyor: probe installed above the belt, material thickness≥10~15mm，vertically aligned with the material flow; most commonly used scenario, feed, grain, wood chips, mineral powder.

Chute / Discharge port: installed at the dryer discharge chute, monitors the drying endpoint, linked with drying heat source adjustment.

Screw conveyor: pipeline sight window installation, suitable for closed powder conveying (lithium battery powder, chemical powder).

Roll pressing / Roll material production line: paper, non-woven fabric, film, using transmission-type near-infrared probe.

Installation distance: conventional 200–350mm，fine-tuned according to material model; materials must not have large voids, ensuring continuous and stable material layer.

Hohes Risiko von Fehlern bei traditioneller Stichprobenprüfung, Online-Nahinfrarot-Feuchtigkeitsmessgerät mit Vollbreitenüberwachung

5. Core technical parameters (general version, can be modified as needed)

Messbereich:0.1%～95%(Customized according to material calibration model)

Messgenauigkeit:±0.1%～±0.3%(Depending on material working conditions)

Response speed: millisecond level, real-time update

Probe protection:IP65，dustproof and waterproof

供电：DC24V / AC220V wählbar

Ambient temperature:0~55℃; high-temperature working conditions optional air cooling/ Water-cooled probe

Output signal:4-20mA、RS485 Modbus，Ethernet optional

Calibration method: laboratory sample modeling, on-site small sample calibration, supports multi-material model switching

Functions: upper and lower limit alarms, automatic data recording, temperature compensation, color difference / Particle interference algorithm compensation

6. Core advantages of the solution

Real-time online, no lag:7×24 hours of continuous monitoring, no longer waiting for laboratory test results, timely detection of moisture fluctuations.

Non-contact non-destructive testing: the probe does not contact the material, no wear, no material contamination, powder, granules, and sheet materials can all be measured.

Reduce production costs: reduce oven testing consumables and testing labor; accurately control drying, avoid excessive drying and waste of heat energy, reduce batch scrapping due to excessive moisture.

Process closed-loop control: moisture signal connected to PLC，automatically adjust hot air and feed speed, realizing unmanned water control on the production line.

Anti-interference industrial design: built-in temperature compensation algorithm, multi-spectral reference band, reduces the influence of material color difference and particle size; optional air purging, prevents dust from contaminating the optical window.

Complete and traceable data: automatically records moisture trends and alarm records, exports reports, meets ISO、factory inspection, quality audit requirements.

Friendly to new and old production line renovation: simple installation, small renovation workload, one controller can mount multiple probes, multi-point synchronous monitoring.

7. Applicable industries and materials

Feed industry: feed pellets, powder, bran

Grain processing: flour, starch, grains

Paper: pulp, paperboard, base paper

Wood and building materials: wood chips, wood powder, density board

Chemical: plastic pellets, various chemical powders, fertilizer granules

New energy: lithium battery positive and negative electrode powder

Tobacco: cut tobacco, tobacco leaf redrying

Pharmaceutical: traditional Chinese medicine granules, medicinal powder

Food: white sugar, milk powder, filling

Coal / Metallurgy: mineral powder, sinter mixture

8. Implementation process (project landing steps)

On-site working condition assessment: confirm production line type, material type, moisture range, dust / Temperature environment, installation location.

Sample modeling and calibration: collect material samples, establish moisture prediction model in the laboratory.

Equipment production customization: probe selection, communication protocol confirmation, supporting brackets and purging accessories.

On-site installation and commissioning: fix the probe, calibrate the optical path, connect to the central control PLC。

On-site calibration verification: on-site sampling and comparison with oven data to optimize the model.

Training delivery: operation training, model backup, maintenance manual delivery.

After-sales operation and maintenance: regular return visits, model maintenance, remote fault support.

9. Operation and maintenance instructions

Daily maintenance: regularly purge the optical window, clean dust; check the fixing bracket and cables.

Model maintenance: when the material formula changes significantly, re-sample and calibrate the model; under normal working conditions, the model remains stable for a long time.

Wear parts: light source regularly inspected and replaced, other components have low maintenance.