Machine and PLC layer
Map analogue signals or digital registers, scaling, status bits, recipes, interlocks and control permissions.
Data and integration
Move from a live value to a usable control decision
The moisture value creates value only when its timestamp, quality state, material identity and process context reach the people or systems that make decisions.
Data and integration
The moisture value creates value only when its timestamp, quality state, material identity and process context reach the people or systems that make decisions.
Operations and quality layer
Trend moisture with line speed, density, temperature, batch, supplier and laboratory references.
Diagnostics and governance
Define alarm ownership, configuration backups, user access, remote-support boundaries and change records.
Software in operation
See how moisture data supports three production workflows
The interface demonstrations below are based on the bale, full-truck and board-analysis functions recorded in current product materials. They show how live values, section profiles, material identity, calibration and plant communication work together.
Demonstration interface · simulated operating data · AI suggestions require operator review and do not replace project rules
Section-by-section moisture inspection on a controlled intake line
Recovered-paper baleBale inspection dashboard
TopMeshMW-6000
DEMO09 Aug 2026 · 14:32:18
LiveTrendsCalibrationRecordsSettings
MW-6000
Bale inspection dashboard
LIVEValidNo active alarm
Average moisture14.93%
Current section12.03%
Bale height0.96 m
Signal CPS29,850
AI
AI analysis assistantWatch
Section variability increased after section 4
The latest profile widens at sections 5-6 before falling at section 8. Check bale position, compaction and height compensation; pair a reference sample if the pattern repeats.
Live moisture trend14:27 - 14:32
Section moisture profile8 / 8
Multi-section incoming-load inspection with supplier and vehicle identity
Supplier 04Full-truck receiving dashboard
TopMeshMW-7000
DEMO09 Aug 2026 · 14:32:18
LiveTrendsCalibrationRecordsSettings
MW-7000
Full-truck receiving dashboard
Inspection completeValidPLC synced
Average moisture10.08%
Current section9.77%
Material temperature22.35°C
Valid sections16 / 16
AI
AI analysis assistantStable
No abnormal load-profile shift detected
Section values remain close to the current load baseline. Confirm scan coverage and vehicle/supplier identity before grading or settlement.
Section moisture profileRC-0809-17
Data stateInspection complete
Classification outputRules ready for review
Plant connectionRS485 · Modbus RTU
Continuous moisture profile, distribution and classification for moving boards
18 mm MDFBoard quality dashboard
TopMeshMW-8000
DEMO09 Aug 2026 · 14:32:18
LiveTrendsCalibrationRecordsSettings
MW-8000
Board quality dashboard
LIVEValidPLC synced
Average moisture7.42%
Minimum moisture6.88%
Maximum moisture8.05%
Material temperature32.6°C
AI
AI analysis assistantReview
Right-centre moisture band is above the board average
Compare the next boards and check temperature, alignment and product identity before changing thresholds or calibration.
Board moisture distributionMDF-18-0809-128
7.17.37.67.87.56.97.27.78.17.86.87.07.57.98.07.07.27.47.77.67.17.37.57.8
6.8%8.1%
Active calibration
Calibration and validation workspace
Reference samples remain linked to the online time window, material and model version before a calibration is released.
| Sample | Online % | Reference % | Data state |
|---|---|---|---|
| S-01 | 6.92 | 7.05 | Calibration set |
| S-02 | 7.38 | 7.31 | Calibration set |
| S-03 | 8.04 | 7.96 | Validation set |
| S-04 | 7.71 | 7.82 | Validation set |
Matched samples12
Calibration set8
Validation set4
Model versionMDF-18-V04
Approval statePending approval
Control objective first
Define the decision before creating PLC tags
A useful integration carries more than one moisture number. It identifies whether the value is valid, which product or supplier it belongs to, when the measured material reaches the control point and how operators can override or acknowledge the resulting action. This definition prevents a live signal from becoming an unexplained tag in the PLC.
Define the decision
State whether the data supports display, alarm, recipe correction, dryer control, classification, supplier comparison or quality release.
Build the signal dictionary
Document engineering units, scaling, update rate, valid and fault states, product identity, calibration version and time source.
Align the process
Match sensor time to transport delay, sample time, actuator response and batch boundaries before calculating averages or control errors.
Test and govern
Simulate normal, high, low, invalid and communication-loss states; then control access, backups and change records for every deployed configuration.
Integration package
What should remain after data integration is complete
The signal map is matched to the selected hardware, software version and plant architecture, including the required analogue, serial or network interfaces.
- 01Signal and register map
- 02PLC/MES data-flow definition
- 03Dashboard and alarm requirements
- 04Backup and diagnostic procedure
Automation context
Interfaces and operating rules needed before mapping data
- PLC/SCADA/MES architecture
- Required protocol and available interfaces
- Tag, unit and update-rate conventions
- Recipe, batch and supplier identifiers
- Alarm and control ownership
- Cybersecurity and remote-access policy
Data-chain failure modes
Prevent valid numbers from driving the wrong action
A value without quality state
Holding the last good value during a fault can drive the wrong action unless validity travels with the measurement.
Incorrect process delay
Comparing a sensor value with the wrong laboratory sample or actuator position creates apparent error even when both measurements are sound.
Uncontrolled changes
A scale, register, recipe or calibration change without version history breaks traceability and makes later troubleshooting slow.
Tell us what you measure, where it moves and how the result will be used
Share a few process details and our application team will recommend a suitable technology, installation concept and validation plan.