Microcontroller board and software for spark detection Erkennung & Bekämpfung von Funken in pneumatischen Absaug- sowie Fördereinrichtungen
In the wood processing sector and related industries (e.g. the food, textile and chemical industries), there is a high risk of fire and explosion due to the generation of sparks in extraction and conveyor systems. A new generation of control units was required for our client Fagus-GreCon’s modern spark suppression system, the ‘GreCon PROTECTOR’, which reliably detects ignition sources, remains operational in the event of a power failure, integrates seamlessly into control and building systems, and reduces installation and maintenance costs.
SYS TEC electronic developed an electronic subsystem based on Single Pair Ethernet (SPE, 10BASE-T1L) and Power over Data Line (PoDL). Data and power are transmitted over distances of several hundred metres via a single pair of wires.
A modular centralised design featuring communication, fieldbus and power supply modules enables high-availability, redundant ring topologies. Thanks to a buffered power supply , the system remains operational without interruption even in the event of mains faults. This ensures that the spark-extinguishing system operates reliably even in critical situations.
Integrated diagnostic and monitoring functions enable continuous monitoring of the system’s condition. This enhances operational transparency: anomalies and faults are detected at an early stage, enabling operators to respond quickly and plan maintenance measures effectively.
The architecture enables easy integration into industrial networks (e.g. PROFINET, EtherNet/IP) and cloud solutions. By utilising Single Pair Ethernet with Power over Data Line, traditional fieldbus cabling and separate power cabling can be largely replaced. Thisreduces the amount of cabling, space requirements, weight and potential installation errors. Safety functions, encrypted communication and a well-designed power management system further ensure a robust and secure communication network.
The design and development of the SPE/PoDL-based electronic system, including hardware, software and communication architecture, are the work of SYS TEC electronic. In this way, we incorporate innovative Ethernet technologies into a safety-critical fire protection system – from the microcontroller assembly right through to system integration.
Why this solution helped our client’s project move forward
With the SPE/PoDL-based central generation system, the customer received a fire protection system that:
- Greater safety through rapid and reliable detection and suppression of sparks and ignition sources
- Greater system availability thanks to redundant communication and buffered power supply
- Significantly reduced installation and maintenance costs thanks to combined data and power transmission
- A future-proof, standards-compliant solution with end-to-end Ethernet communication from the sensor to the control or cloud level
The modular, Ethernet-based architecture reduced project and operating costs, increased plant and operational safety, and created a future-proof platform for modern, networked fire protection systems in demanding industrial environments.
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