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UniMAT's Successful Integration in the Building Materials Industry: A Case Study

UniMAT's Successful Integration in the Building Materials Industry: A Case Study

The building materials industry relies on advanced automation solutions to optimize production processes and meet the increasing demand for quality construction materials. This case study highlights the successful collaboration between UniMAT, a fictional service company specializing in industrial automation, and BuildTech, a prominent building materials manufacturer. UniMAT implemented their expertise using the SR40 CPU, a reliable programmable logic controller (PLC), in a project that has been running smoothly without any reported issues.

Client Overview:
BuildTech is a leading building materials manufacturer, producing a wide range of construction products known for their quality and durability. To enhance their manufacturing efficiency and maintain their competitive edge in the market, BuildTech sought to integrate advanced automation systems.

UniMAT's Solution:
UniMAT, a trusted provider of industrial automation solutions, proposed a tailored automation solution to address BuildTech's specific requirements. The SR40 CPU, known for its stability and versatility, was selected to provide precise control and monitoring capabilities throughout BuildTech's production processes.

Implementation and Integration:
UniMAT's automation experts closely collaborated with BuildTech's engineering team to understand their manufacturing workflows and identify opportunities for automation optimization. Based on the analysis, the SR40 CPU was chosen for its robust features, efficient programming options, and compatibility with BuildTech's existing infrastructure.

Installation and Commissioning:
Following the solution selection, UniMAT's skilled technicians proceeded with the installation and commissioning phase. They expertly integrated the SR40 CPU into BuildTech's manufacturing processes, ensuring seamless wiring, configuration, and programming. Rigorous testing and quality checks were performed to verify the system's functionality and reliability.

Operational Performance:
Upon completion of the installation, BuildTech experienced a significant improvement in their manufacturing efficiency and product quality. The UniMAT solution, powered by the SR40 CPU, offered precise control and real-time monitoring, allowing BuildTech to optimize their production lines. The automation system streamlined operations, reduced wastage, and increased overall productivity.

Stable Operation and Reliability:
Since the implementation, the UniMAT solution integrated with the SR40 CPU has been operating without any reported issues or disruptions. BuildTech commends UniMAT for the system's stability and reliability, which have contributed to uninterrupted manufacturing operations and consistent product quality.

The successful collaboration between BuildTech and UniMAT exemplifies the positive impact of automation in the building materials industry. By integrating UniMAT's solution, utilizing the reliable SR40 CPU, BuildTech achieved improved manufacturing efficiency, enhanced product quality, and streamlined production processes. UniMAT's commitment to delivering reliable and robust automation solutions ensures that companies in the building materials sector can achieve operational excellence and maintain a competitive edge. This case study showcases UniMAT's expertise in providing seamless automation integration and highlights the benefits of leveraging advanced technology to drive efficiency and reliability in the building materials industry.
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Transformation of electric system in punching machine

Transformation of electric system in punching machine

First, preface




The press of several production lines in an automobile factory is the equipment manufactured by German SCHULER Press Company in the 1990s. The S5 series PLC of SIEMENS Company is used to realize the core control and critical protection of the punching machine tool. It has been continuously produced for more than ten years since it was put into use. At present, the Siemens S5 control system used by the press company has been more stringent. Serious aging, rising failure rate, and many electrical control equipment due to a long period of time, Siemens no longer production and supply, spare parts supply exists a great risk, if not changed in time, will press maintenance and normal high-efficiency production bring great hidden dangers, in order to solve the maintenance problems faced by the press, will look at The previously used Siemens S5 control system was upgraded to the widely used Siemens S7 control system to fully ensure the normal and efficient operation of the press.

Two, system overview


With China's accession to WTO, foreign automobile factories have invested in China to build factories. There are many kinds of automobiles with different styles. The development of stamping production enterprises is more and more closely linked with the automobile industry. The object of this transformation is 600 tonnage closed punching machine. The schematic diagram of system control is as follows. When the punching machine is working, the flywheel is driven by a motor through a belt wheel, and the crank-slider mechanism is driven by a gear pair and a clutch. The rotating motion of the flywheel is converted into the up-down motion of the slider to complete the stamping of the workpiece. The slider moves from the highest point to the lowest point to complete the stamping of the workpiece, and then returns to the highest point to break the clutch and complete a working cycle. In order to adjust the size of the slider on the workpiece in order to better complete the stamping of the workpiece, an air cushion is installed under the moving table, and the press is pressed at the prescribed pressure by adjusting the pressure of the compressed air inside the air cushion. In the stamping process, because the weight of the slider will have an important impact on the motion of the whole system, a balancing device is used to hold the slider with compressed air, so that the weight of the slider is zero, and the power of the slider movement is completely provided by the flywheel. Thus avoiding the influence of slider weight on the system. Each press can replace different die stamping different workpieces, in the replacement of the mold will be put down the air cushion, the slider mounted on the punch unlocked, placed on the moving table above the die, slider open to the highest point, and then through the moving table to open the mold, the new mold into.

The system consists of the following parts:


1. the core control system of punching machine is made up of S5-155U.

2. peripheral devices driven by S5 I/O

3. the upper monitoring and data management system is composed of WF470.

4. parallel encoder monitoring system slider, air cushion height, cam angle

5. WF715 constitutes a cam safety control system.


Three, system requirements


1) Extending the service life of the machine - because the press is the key equipment in the automobile production line, the normal or not of the equipment is directly related to the operation efficiency of the entire automobile production line, and the equipment of a single press is expensive. Since the life of the mechanical part of the press is about 50 years, and the life of the electrical part is generally only about 15 years, so in the life of the press about three times to reform the electrical equipment.

2) Reduce the cost of spare parts, good maintainability - in order to achieve good maintainability after the system transformation, a variety of hardware modules choose standardized series, should be selected with good development prospects of technology products, so as to ensure the long-term supply of spare parts in the future. The software is modified on the basis of the original S5 program, which not only guarantees the consistency of the reformed system, but also customizes the control function according to the user's requirements, and adds necessary annotations to ensure the readability of the program code. Therefore, there is no problem in the maintenance aspect. All kinds of development documents are well preserved and archived regularly in time to ensure the readability of the program code. The maintainability of software;

3) Quick replacement reduces downtime by only 4 weeks - in order to save time and labor in site construction, shorten downtime and reduce the impact on production. Prepare for the transformation: which needs to be replaced and which remains in the system, and make a reasonable arrangement and division to prevent blindly expanding the scope of transformation and omission of transformation projects. All wiring and the control points in the program are exactly the same.

4) All-Chinese operation interface and powerful diagnostic system-all-Chinese operation interface make it easy for operators to understand equipment status, modify process parameters, provide output query, and facilitate production scheduling. At the same time, the fault and alarm information are displayed intuitively in the upper computer graphically, and the communication status of each node in the system is displayed.

5) Customize the control function according to the user's requirement - while keeping the original operation mode unchanged, add the corresponding monitoring function according to the actual needs of the site.



Four. System design


1, design plan

As the press is the key equipment in the automobile production line, whether the equipment is normal or not is directly related to the operation efficiency of the entire automobile production line, and the equipment of a single press is expensive. Therefore, in the process of transformation, the requirement is 100% safety and 100% success rate. In view of the above situation, the following plans are adopted in the whole project transformation process:

1) in the process of the whole system transformation, debug the software first and then rebuild the electrical equipment.

In order to reduce the transformation risk of the whole project, all S5 equipments are not moved at first, and a PROFIBUS communication card is added to the S5 system. All the equipment signals in the S5 system are transmitted to the S7 400 CPU through PROFIBUS communication. The S7 400 CPU replaces the S5 control CPU. The control program of a device runs in S7 400, and the external control signals are all driven by the template of S5.

In the whole project implementation process, by adding a switching program in S5, the S7, S5 system can be freely switched to control the machine only by modifying the parameters, and the whole system replacement process can be completed within three hours, to achieve no risk transformation.

2) The whole electrical equipment renovation follows the principle of systematic upgrading, according to the press control process requirements, S5 controller is upgraded to S7-400F controller to increase the safety protection function.

The safety control system is a control system specially used for interlocking in dangerous places and emergency parking. The essential difference between PLC and ordinary process control is that its function is to make the device stop safely under the condition of accident and failure (including the device accident and the control system itself failure), to avoid the damage to the personnel of the device and to the environment. If a critical application scenario occurs, the controller can enter a user-defined security state to execute the downtime program in a predetermined order, and then provide the user with diagnostic data information reports.

For user's convenience in equipment maintenance, the modification process ensures that all program structures, electrical wiring, and instructions are substantially consistent with the original system, and that all modifications are detailed and annotated. In addition, all programs, variable tables are added in Chinese annotation, to bring convenience to maintenance personnel.

3) The monitoring screen uses a WINCC data monitoring server as the main monitoring computer of the whole system and a touch screen with an electronic disk as the machine monitoring interface.


Because the vibration of the press will cause very serious damage to the hard disk of the computer, it is required that the monitoring computer installed on the machine can not have hard disk, and the control process of the whole production line requires that all data management must be unified by the computer. In order to solve the above contradictions, the whole system is managed by two computers. A BOX PC is installed in the electric control cabinet to realize the data management of the whole system. The management software is implemented by the Siemens monitoring software WINCC, and the operating system adopts the stable and reliable WINDOWS 2000. Another computer uses Microsoft's WINCE as its operating system. The entire computer does not have a hard disk, and the data is stored on a 2G electronic disk.


Using the special monitoring software NETC@P imported from Germany, the WINCC software on BOX PC is monitored remotely. Compared with other remote control software, NetC@p software specializes in real-time services, and is easy to control the operation process. The system runs out of software in the form of a graphical display card, so all applications are displayed on a personal digital assistant or mobile tablet computer without additional software programming. NetC@p is responsible for analysis and adjustment. The software installed on the host is like a terminal emulator that packages images, mouse and keyboard information onto Ethernet for slave use. The slave is often used as a client application or mobile terminal (with Windows CE as the operating system), and on the slave, the NetC@p application will automatically start running. No other programs or devices are needed. Through a set network, or ISDN and DSL network connection, only pre-set connection parameters, and input the system, that can easily achieve remote operation and analysis, significantly saving time and cost.

4) encoder is replaced by PROFIBUS DP bus structure encoder.

The original TTL level absolute encoder is replaced by an encoder with PROFIBUS DP interface. PROFIBUS DP network can provide 12Mb/s transmission rate and excellent anti-jamming ability, which makes the control accuracy and anti-jamming ability of the new system far stronger than the old system.

5) S7I/O module adopts distributed I/O system ET200M module, the module uses UNIMAT's UN 300 series module, and uses PROFIBUS DP bus structure between CPU and S7I/O module.


2, system configuration

The upgrade table of the whole automatic control equipment is as follows. The main electrical control equipment of the automation will be replaced by a new control system.

After modification, the electrical diagram of the system is as follows:


3, control system function upgrade


1) adopt S7 400F fail safe controller and signal module.

The controller of the system adopts Siemens S7 400F fault-safe controller and compiles the internal integrated cam control software of S7 400 to realize the cam control. It replaces the original cam controller WF715. While increasing the control flexibility, the electronic cam and the electronic cam are controlled by the safety function module provided by the fault-safe controller. Cam encoder communication carries out safety monitoring to ensure system safety and avoid damage to operators.


2) data exchange between S7 system and computer using Ethernet.


Ethernet communication module CP443 is added in the system to exchange data between Ethernet and the upper computer of the whole system. At the same time, the interface is provided for the networking of the whole production line. The operation of any press in the unit where the press is located can be monitored on each press, which brings convenience for maintenance.

3) Using the special remote monitoring software NETC@P, the data exchange between the press display terminal (slave) and the PC BOX (host) is realized through Ethernet.

In order to avoid the damage to the computer caused by the working vibration of the press, two computers are used to complete the monitoring of the whole system. One uses a high-reliability Siemens PC BOX industrial computer as a server to store data and install all the control software. The other runs a special operating system as a client display terminal. Remote access to the server; an electronic disk is installed on the client's computer without any moving parts to avoid damage to the computer's life due to the vibration of the press.

The host can identify all registered slave machines and assign only one operation right to a slave at a time. When the command is entered on the console in the control room, a red or green traffic signal-like light is lit. Avoid simultaneous operation or erroneous operation. Operators can also pre-set the host computer to decide whether it is the host computer that makes the decision whenever a slave computer applies for the right to operate, or whether the slave computer automatically allocates the right to operate to the slave that first makes the application. Thirdly, if it is necessary to authorize an operator to have the right to operate, it can also use a password, or a password switch to lock the scope of the right to operate, to maximize the security of the system operation.

4) WF470 upgrade to WINCC

The upper computer software is upgraded from WF470 to WINCC, and the upper computer is upgraded to 15 inch touch screen operation mode.

With the powerful function of WINCC, the system has added the following functions:

(a) Mandarin/German language switching function to facilitate the daily operation of workshop operators and the regular maintenance of manufacturers;

B) Display the status of PLC input, output and analog input and output on the PC, which is consistent with the actual layout of the PLC module in the electronic control cabinet, and each point of each channel is accompanied by detailed notes;

Fig. 3 status display of PLC I/O module

C) Through the powerful storage function of WINCC, 100 sets of mold data management are added, and the technological parameters of the mold are stored in the mold formula beforehand, and the corresponding mold parameters are only exported during the production, which greatly improves the mold changing speed, improves the production efficiency and facilitates the unified management of the mold and reduces the misoperation.

Fig. 4 formulation of mold data

D) increase the operation authority management of mold data. After the system upgrade, the operator can only set the mold parameters up and down in the range of data derived from the formula, and the setting is invalid if it exceeds the range. Setting range can be set by machine tool maintenance personnel to reduce the damage to the mold caused by misoperation; increasing the height of the slider twice, integrating the data of the two adjustments into the mold formula, just click the button to realize the height setting, easy and comfortable operation; realizing the height of the slider and the air cushion adjustment at the same time, changing the mold operation. Fast and stable.

Fig. 5 parameter setting of mold data

E) super strong fault diagnosis system, adding operation information record. After the system upgrade, in addition to retaining the original fault records of the system, some important operations on the machine tool panel and all parameter setting operations for the mold are recorded, which is convenient for fault detection and clear responsibility.

Fig. 6 operation information record

F) super system diagnosis function, increase encoder calibration, sensor and transmitter calibration. After the system is reformed, the complex calculation of parameter calibration is realized by program. In actual operation, the calibration can be accomplished only by directional guidance according to the calibration and by measuring the height or pressure, temperature and so on.

Fig. 7 encoder calibration

5) encoder is connected by PROFIBUS network

The encoder of the whole system is connected by PROFIBUS network, and the encoder of slider adjustment and air cushion adjustment is connected by a special PROFIBUS network. The cam encoder is connected by an independent PROFIBUS network, mainly considering that the electronic cam encoder is the core control of the press control system and has been running in the press. Fast real-time response is needed in the process. The maximum communication rate of PROFIBUS network can reach 12 Mb/s, which guarantees the encoder detection accuracy and communication quality.


Five, transformation effect analysis

1) safety aspects

S5 and S7 are used to run in parallel, and S5 is dismantled after confirming the reliability of S7 control system to ensure the risk-free transformation.

2) technical indicators

The key parameters of the press, such as slider, air cushion height, balancer and air cushion pressure, all meet the technological requirements, and the quality of the mold products is well controlled.

3) production efficiency

By introducing new formula technology and full Chinese operation, it can effectively increase the speed of mold change and reduce the intensity of work.

4) economic benefits

With the successful experience of the first press upgrade, the process of the press upgrade became more standardized, the period of the upgrade was shortened by one third, the high efficiency of the upgrade was achieved, and a lot of maintenance costs were saved. The SIEMENS compatible module of UNIMAT also saves cost.

Six, concluding remarks


Through this transformation, all the original control functions have been realized, and on the basis of the original operation monitoring functions, such as formula change, operation record query and other user-customized practical functions have been realized, which provides a powerful tool for the factory to carry out production management and accident analysis. At the same time, because S7 is more powerful than S5, both system response speed and maintenance and debugging have been greatly improved. Up to now, the system has been running safely and stably for more than half a year, and has been widely praised by factory operators and managers.

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Application of DCS control system in a Cements Limited

Application of DCS control system in a Cements Limited

1.System overview

Project Scope: To provide a complete DCS for the new dry process cement production line with a daily output of 2500 tons, to meet the needs of cement production, and to provide stability guarantee for the production of high quality cement. The overall goal of control system design is:

Provide reliable operation environment for producing high quality cement.

Improving the automation level of the entire cement production line.

To achieve high quality operation of units and improve operation economy;

To improve the working efficiency of the operators and meet the requirements of the crew running on duty.

Improve efficiency and reduce energy consumption.


2.The design idea of system design and application.


1) Functional design: embody the degree of automation after the completion of DCS, the ability to deal with accidents (alarm, analysis, guidance, treatment, etc.) and advanced control strategies, to maximize efficiency, reduce energy consumption as the design idea. The details are as follows:

Object control

The process of automation is coordinated by the DCS system to achieve energy balance.

Ensure the safe, reliable and efficient operation of the unit and start and stop

Improving technical and economic benefits of unit operation

The unit runs at the upper limit of the rated parameters, so that the unit is in the best operating condition.

To achieve high automation input rate, improve reliability, reduce misoperation and reduce accident rate.

Perfect operation guidance and accident analysis means.

The operating conditions of the unit can be reflected by many monitoring parameters. When abnormal operating conditions occur, on the one hand, the overspeed function and process restriction mechanism are implemented, on the other hand, relevant parameters, trends, charts and other efficient ways are provided to inform the operators to deal with in tim

Operation record printing, alarm printing, accident recall printing, periodic report forms and other functions are conducive to the daily management of the unit and accident analysis.

Efficient and convenient system online maintenance.


2) system design: it embodies the design idea of DCS's high reliability, advanced nature, easy maintenance and easy configuration. The details are as follows:

reliability design

All components are standardized, universal and modular.

Control system should be stratified, decentralized and autonomous.

All I/O modules are designed intelligently with isolation measures and high common mode rejection ratio and differential mode rejection ratio. And have

Software digital filtering and elimination of accidental interference.

Maintainability design

System self diagnosis to channel level.

Selecting modular functional configuration software to improve software transparency.

Expansibility design

Adopt industrial Ethernet network structure, communication rate is 100 mpbs, backbone network is redundant ring network, each sub-station is connected to the backbone network through twisted pair cable, which has strong communication expansion ability.

Provide communication interfaces with other systems, such as industrial Ethernet, PROFIBUS DP or MODBUS.

Open design

Support international standard data interfaces, such as OPC, ODBC, OLE, DDE, SQL and so on.

Support SIS system to realize DCS data monitoring.

Three system configuration and function realization

According to the characteristics of cement production and the design and distribution of I/O points, the following design schemes are carried out. The basic functions of the design include: raw material mixing system, raw material grinding system, raw material homogenizing system, firing system, kiln head system, coal grinding system, power system, alarm system and trend chart. The system is designed according to the process flow. The following are the following:

1 raw material batching system

The control system mainly carries on the automatic control to the iron powder, sandstone and limestone level gauge, which is the raw material for cement production, and realizes the reasonable and high efficiency ratio of each raw material. The purpose of batching is to determine the consumption ratio of various raw materials and fuels and to produce cement clinker with high quality, high yield and low consumption. The principle is that the raw meal prepared is easy to grind and burn, the clinker produced is of high quality, the production process is easy to operate, control and management, and simplify the process.

2 raw meal grinding system

Grinding is the process of breaking small pieces of granular material into fine powder. Raw meal mill is a process for grinding raw materials into raw meal after grinding. It mainly includes raw meal mill, separator and dust recovery function. Reasonable raw meal grinding system is of great significance to ensure the quality and output of raw meal, improve the quality and output of clinker, and reduce the power consumption per unit product.

3 raw meal homogenization system

Raw meal homogenization is the use of air stirring and gravity under the effect of the "funnel effect", so that raw meal powder falling down when cutting as many layers of material surface as possible to be mixed. At the same time, under the action of different fluidized air, different sizes of fluidized expansion will occur along the parallel material surface in the reservoir. Some discharged materials in the reservoir area, and some fluidized in the reservoir area, so that the material surface in the reservoir will produce radial tilt and carry out radial mixing homogenization.

4 firing system

The firing system is the process of converting raw meal into clinker, which directly determines the output and quality of cement, the consumption of fuel and lining, and the safe operation of rotary kiln. The key technologies are suspension preheating, calciner and rotary kiln, which undertake the preheating, decomposition and firing of cement clinker respectively.

5 kiln header system

The function of grate cooler in kiln head system is to realize gas-solid heat transfer between clinker and cooling air efficiently and quickly. When the clinker is quench, there is also the heating and warming task of two times of entering the kiln and three times of entering the furnace.

6 cement grinding and packaging for the latter stage of construction, has not yet started.

7 power system

It is mainly for real-time monitoring of raw material power room high voltage cabinet and firing power high voltage cabinet.

8 network configuration

The control stations of cement production are very dispersed, and the safety of the system depends largely on the stability of the control network. The design and application of redundant optical fiber ring network technology make our process control.

 Report error

From the hardware structure, the system can be divided into:

1. operator station (OS station) and engineer station (ES station)

The DCS system is equipped with four independent operator stations (OS stations), including remote batching, raw meal grinding, firing kiln tail kiln, kiln head and coal mill, one OS station, namely, four operator stations (each operating station with 24 inch LCD), and one ES station in the central control room. Each set of OS adopts a mature and reliable DELL commercial computer.

OS station provides graphics, lists, operations, historical data reproduction for the operator, and can be output on the printer. Run WINCC6.2 application software under Windows XP multitask network operating system. All OS stations are all-round duty configuration, image, operation, data consistency, to achieve on-site start-stop, monitoring, data storage operation.

The system is equipped with 1 sets of engineer stations (ES station) and a mature and reliable DELL commercial computer.

ES station mainly completes the generation and downloading of real-time database, control block, graphics, trends, reports and other system data, completes the detailed self-diagnosis of the system and the list and backup of system data. Run the STEP7v5.4 and WINCC6.2 application software under the Windows XP multitask network operating system.

The system can be configured and maintained by electrical professionals through the engineering station. Professional engineers can modify the system online or offline on the spot. At the same time, all operating conditions and control logic can be viewed on the engineer's station, which increases the degree of user's mastery of the system, as well as the transparency of system software and hardware. When no configuration is needed, the software that runs exactly the same as the operator station can be run.

The whole system is equipped with 2 network printers for recording printing and CRT image copies. Printer selects HP network printer.


2. remote I/O station

The system is composed of Siemens CPU and remote I/O station of Uygur UNIMAT. Each distributed I/O station adopts Uygur UNIMAT's UN 300 series module, and communicates with PROFIBUS-DP through 153 interface module and S7-400 central control station. Among them are UN 300 series UN 321-1BL00-0AA (32DI), UN 322-1BL00-0AA0 (32DO), UN 331-1KF01-0AB0 (8AI), UN 331-7KF02-0AB0 (8TC), UN 332-5HD01-0AB0 (4AO), which not only saves costs but also reduces energy consumption.

3. redundant communication network

CP443-1 as a standard industrial Ethernet connection device, in the physical layer using a high level of protection of communication cables, industrial Ethernet cards with CPU can handle communication signals independently. High-speed industrial Ethernet is based on the communication protocol of industrial Ethernet, which increases the communication rate to 100M/s. High-speed Ethernet in SIMATIC NET uses full-duplex parallel (FDX) communication mode, which allows stations to send and receive data at the same time, and the communication rate can be doubled. SIMATIC NET also uses switching technology on high-speed Ethernet. The whole network segment is divided into several subnets by using switching module. Each subnet can independently form a data communication network segment, which can greatly improve communication efficiency. Due to the existence of data communication congestion on the network segment, the actual communication technology on the network is only 40%. With full duplex parallel communication technology and switching technology, the communication capability of the network can be fully utilized.

Four, control points and Strategies of cement production


Cement production process equipment has large capacity per unit, continuous production, high speed and coordination. In order to improve the production efficiency and competitiveness of enterprises, the implementation of automatic control is very important. The combination of Siemens CPU and the remote I / O station of UNIMAT can satisfy the control requirements of cement industry, which is mainly based on switch quantity, supplemented by analog quantity and accompanied by a few adjusting circuits.


1. Limestone crushing and conveying system


The equipment of limestone crushing and conveying system has interlocking relationship. The equipment is controlled sequentially according to the principle of "starting up in reverse flow and stopping in downstream flow". The control difficulty of the limestone crushing and conveying system lies in the automatic control of the feeding quantity of the limestone crusher. The speed of the plate feeder can be adjusted automatically by the change of the power of the crusher so as to keep the speed within the required range of operation, so that the material in the limestone silo can not be unloaded because of the high speed of the plate feeder. The plate feeding machine plays a certain protective role for the equipment.

 Raw meal preparation system

Flowchart of raw meal grinding (refer to raw material mill 1.bmp)


The technological process range of raw material preparation system: from the bottom of raw material dispensing station to the top of raw material homogenization storehouse, including raw material dispensing and transportation, including raw material grinding, raw material transportation into storehouse. The control points and strategies are as follows:


Raw meal quality control (QCS) system


QCS system (quality control system) is widely used in cement production. The raw meal quality control (QCS) system consists of an on-line calcium-iron fluorescence analyzer, a computer and a speed-regulating electronic belt scale. Intelligent on-line Ca-Fe fluorescence analyzer can automatically sample, sample preparation and continuous measurement, calculate the burden by QCS system, and adjust the proportion and control the composition of the material by DCS, so as to keep the three-rate value of raw meal fluctuated near the target value, thus greatly improving the qualified rate of raw meal ingredients. And quality stability.


Raw meal grinding load control system

The control difficulty of the raw meal grinding control system lies in the load control of the mill. When the feed moisture and hardness change, the system ensures that the mill is in the best grinding state with stable load by adjusting the feed material quantity to avoid blocking or air grinding. The usual adjusting methods for load automatic control system are: setting a constant of grinding input, and adding new feeding quantity to the grinding input of the separator under steady state is equal to it; secondly, adjusting the power of the elevator or the electric signal of the mill as the main control or monitoring signal in time; thirdly, adjusting the grinding return, lifting function and electricity of the separator. Mathematical models of ear and other signals are analyzed or controlled or extreme value controlled.


Most of the vertical mills are controlled by constant, while the ball mills are mostly controlled by electric ears or hoist power signals.


3. Raw meal homogenization storehouse control

Fig. 4 flow chart of raw meal homogenization storehouse (refer to raw meal homogenization system 1.bmp)

Raw meal pre homogenizing system


Raw meal pre homogenization is achieved by controlling the bottom discharging electric vibrator. Raw material pre-homogenization storehouse is usually a long bar storehouse. There are 26 electric vibrators at the bottom of the storehouse, which are divided into two groups. Each group has 13 electric vibrators, each of which can be controlled by time program separately. The two electric vibrators are controlled by a programmable controller (PLC) according to a certain time program, so as to achieve the pre-homogenization of different time feeding according to a certain proportion. Get into the mill.


Raw meal homogenization system


Homogenization of raw meal is based on air blowing with uniform pressure to homogenate raw meal. Usually an air-filling device is installed at the bottom of the reservoir, and the time sequence control strategy is adopted. According to the time sequence, the air-filling solenoid valve at the bottom of the reservoir is opened and stopped to make the material fluidized and agitated, and the raw material is mixed to achieve the goal of homogenization.


Automatic control system for measuring stock quantity


The opening of the electric flow valve on the side of the raw material warehouse can be adjusted automatically by the weight signal of the measuring silo, so that the material quantity of the weighing silo can be kept stable, so as to ensure the stability of the discharge quantity of the measuring silo.


Blanking control of raw meal homogenization storehouse


In the production process, the firing zone temperature is generally required to be controlled in a suitable range, because it is very important to the quality of clinker. The setting value of raw meal discharge is set by combining raw meal volume, fan air volume and firing zone temperature. The system can automatically adjust the opening of the electric flow valve under the measuring silo by using the feedback value of the solid flowmeter, so that the raw meal can be stabilized on the setting value, so that the raw meal into the kiln can be kept stable, and ultimately the kiln can be guaranteed. Stable operation of the system.


4. Pulverized coal preparation system


Report errors

Flow chart of pulverized coal preparation (refer to "coal grinding system 1.bmp")


Automatic control of gas temperature in grinding mill


The temperature of grinding gas is directly related to the moisture and safety operation of the finished products. In order to ensure the production of qualified pulverized coal, and at the same time to ensure that the system temperature can not be too high, the control system set up the mill outlet gas temperature automatic control loop, by changing the mill inlet cold air valve opening to control the mill outlet gas temperature stability.


Automatic load control of mill


The change of pulverized coal quantity in the pulverized coal bin will affect the metering accuracy of the part of pulverized coal feeding. The amount of pulverized coal in the pulverized coal bin should be as constant as possible in normal production. At the same time, the normal and safe operation of the mill should be guaranteed to prevent "full grinding". An automatic control loop is adopted to automatically adjust the feed quantity of the grinding head quantitative feeder by the electric ear signal of the mill.


5. Firing system

Kiln end flow chart (refer to firing system 1.bmp)


Metering and automatic adjustment of coal feed in calciner


The temperature of calciner is an important control parameter to ensure the normal operation of rotary kiln. The mixing ratio of fuel and air must be properly controlled when the raw meal volume is constant. Therefore, the temperature of the decomposition furnace is measured in order to achieve optimal control. The temperature of the decomposition furnace is adjusted by automatically increasing and decreasing the amount of coal, so that it can be controlled at the desired set value. Not only can the calciner maintain the highest decomposition rate, but also can not cause the raw meal to bind because of the high temperature, which affects the normal operation of the kiln system.


Regulation of outlet pressure of preheater


The outlet pressure of the preheater is a main index of the air balance of the reaction system. The outlet pressure of the preheater is controlled by adjusting the valve opening of the high temperature fan.


Automatic purging device for preheater


In order to prevent the crust blockage from affecting the normal operation of the preheater system, the computer turns on the corresponding solenoid valve on the preheater in a certain time sequence regularly, opens the compressed air pipeline in turn, and purges the preheater step by step to prevent the crust blockage from affecting the normal operation of the preheater system.

Kiln head flow chart (refer to kiln head system 1.bmp)

Automatic control of kiln head negative pressure


The negative pressure of kiln head represents the balance between the ventilation in the kiln and the two air entering the kiln. According to the negative pressure of kiln head, the valve opening of the exhaust fan of electrostatic precipitator can be adjusted automatically to control the balance among the secondary air volume at kiln head, the third air volume at kiln tail and the waste gas volume at kiln head, so as to achieve a stable balance between calcination and cooling clinker.


Speed control of rotary kiln


The strategy adopted is to maintain the balanced and stable production of the whole kiln system by properly adjusting the rotary speed of the rotary kiln on the premise of stabilizing the raw material and fuel quantity.


Automatic adjustment of air volume in one or two chamber of grate cooler


Secondary air has a great influence on the combustion quality, stability and fuel consumption in kiln. The control aim of the system is to stabilize the fresh air flow into the kiln by stabilizing the air flow in the first and second chambers, so as to provide conditions for the stable operation of the kiln.


Automatic adjustment of material layer thickness of grate cooler


Controlling the bed thickness of grate cooler can stabilize the secondary air temperature to stabilize the normal operation of the kiln, and make the clinker achieve the best cooling. Because it is difficult to measure the thickness of grate cooler bed, the pressure under grate is used to adjust the grate speed in order to stabilize the thickness of grate cooler bed. For the two stage grate cooler, it also involves one or two stages of grate speed regulation.


6. Exhaust gas treatment system


The key of the waste gas treatment system is to control the spray quantity of the humidifier. The control strategy is to control the number of nozzles according to the outlet temperature of the humidifier, so as to improve the dust collection efficiency of the electrostatic precipitator by humidifying and cooling. The outlet temperature of the humidifier is generally controlled at about 130 degrees.


7. Cement grinding and conveying system


Feed quantity control


The feeding quantity is uniform and stable, and the feed quantity is adjusted by grinding the sound signal and the power of the hoist.


Automatic control of gas temperature in grinding mill

The gas temperature is controlled by adjusting the ventilation volume of the mill.

Adjustment and control of separator

Storage and transportation of clinker

There is a process interlocking relationship between conveyor and storage equipment. The equipment is controlled sequentially according to the principle of "start-up in reverse flow, stop-down in parallel flow".


8, power system

Four use effect analysis


The DCS system is composed of Siemens CPU and long-distance I/O station of Uygur UNIMAT. It has been running steadily and reliably since its completion. The control precision fully meets the design requirements. It not only saves the cost, but also reduces the energy consumption, improves the efficiency, and fully achieves the expected goal.

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Application in building material production line

Application in building material production line

With the rapid development of electronic technology, PLC is more and more widely used in building materials production line. On the basis of accepting the control form of PLC as the core, due to the market competition and the different cognition of domestic customers, it not only requires the PLC to be as stable as possible, but also requires the cost of the whole control system to be as low as possible. Basically, it is a contradiction at home. This article mainly discusses the solution and application plan of this problem.


Two. Abstract:


By describing the successful case of the application of PLC module developed independently by Shenzhen UniMAT Automation Technology Co., Ltd. in concrete mixing station and aerated block production line to realize the automation of building material production line, the application scheme of UniMAT module in building material production line is put forward, and the stability of UniMAT module in practical application is also discussed. Performance and price advantage.


Three, key words:


Concrete mixing station, aerated block, S7-200, S7-300, keyboard scanning, weighing ingredients.


1. Introduction


We will continue to discuss the concrete mixing plant as a kind of building materials industry, because it has the following characteristics as a whole:


A, the production environment is bad, the dust is large, and the vibration is increased.


B belongs to process control, logic flow is much, logic of equipment is relatively complex.


C. Most of them are equipped with weighing and batching technology, which requires high precision and efficiency, and the equipment runs quickly.


D, the customer's equipment maintenance ability is low, the control system and electrical equipment stability requirements are higher.


E, customers request investment as low as possible.


The self-developed modules compatible with Siemens S7-200 and S7-300 are applied to the concrete mixing station control system and the aerated block production line control system respectively in the building materials production line. In this case, UniMAT PLC fully demonstrates its strong stability and price advantage.


2, application plan


2.1 concrete mixing station control system


Concrete mixing station mainly realizes the measurement of raw materials such as sand, stone, cement, fly ash, water and additives, and feeds the mixer according to a certain set order, mixing for a period of time and discharging. The main characteristic of the production line is the difficulty of control.


A. Require high efficiency, equipment is intermittent operation, but the production efficiency as close as possible to the continuous operation;


B. High mixing accuracy. The national standard requires that the dynamic metering accuracy of sand and stone is less than 2% and the accuracy of powder and liquid materials is less than 1%. Especially for additives, the dosage of additives is sometimes 10 kg, and the error can not exceed 0.1 kg. This is still in the occasion where the vibration of mixer is especially large.


C. The requirements of production management are relatively high. It requires full recording of production data, including any manual operation by the user. All manual operation signals are required to enter the microcomputer through PLC.


The I/O points of the whole system are about 120, and the DI and DO points are almost the same. In order to solve the above problems, we adopt 214 CPU modules of Siemens S7-200 PLC. The remaining I/O modules and the AI modules used for moisture content measurement adopt the series of 100 million-dimensional UN200. The batching measurement adopts the batching control instrument PLY600 developed by Shandong Boshuo himself. Realization. In the UN200 module, the 8DI/8DO digital module is used as the keyboard scanning module to collect the signal of manual operation. The system structure is as follows:

2.2 air entraining block production line control system


Aerated block production line is also a harsh application environment, the control system of dust resistance and other aspects of the test is very strict. In the past, we mostly used Siemens S7-300 PLC, the overall cost of the system is high, many users reflect that they want to reduce the price, but ultimately accept the high price, contact with billion-dimensional modules, after testing, we decided to use UN-300 series of modules instead of the corresponding AI, DI, DO modules, using Siemens 313C-2DP CPU, using the power module of 100 million dimensions, the system structure is as follows:

3. Conclusion


The construction material production line of Shandong Bo Electronics Co., Ltd. has been integrated with the billion-dimension module for five years. Its PLC performance is stable and the quality is reliable. At the same time, our scheme has been recognized by more and more customers, which fully meets the needs of the vast number of building material customers. The practical application shows that the billion-dimension module greatly improves the production of building materials. Online production efficiency and economic benefits.

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Application in cement leakage board production line

Application in cement leakage board production line

With the development of modern and intelligent pig farming in China, more and more pig farms begin to use leaky floor, and all of them are European or American cement leaky board. Why? Because the production of cement leakage board in China mostly adopts manual or semi mechanical semi manual way, the quality is good and bad, and there is still a big gap compared with the cement leakage board in Europe and America *, and the quality of the leakage board will directly affect the quality of pig hoof hoof. So how to solve the problem of quality caused by manual work, but also greatly improve the production efficiency? Xiaobian today to introduce a solution system - billion-dimensional PLC control system.


01The fully mechanized production line of cement leaky seam slab realizes mechanized operation from concrete mixing, concrete distribution, vibration, pulping, surface treatment (polishing), overturn demoulding, on-line steam curing, finished product off-line, etc. The process adopts computer control technology.+


control object

The production line needs to control 2 inverters and 8 motors. Mainly control the opening, closing, stopping and running of field equipment.

The opening and closing of electric valves, the linkage of key equipment, and the automation of production process.


It is necessary to equip with panel control equipment, the emphasis is to maintain stable operation for a long time, so the product quality requirements are high.






PORT0: PPI protocol for communication between panels and CPU

PORT1:CPU and inverter communication MODBUS protocol

PLC programming


It has 14 digital input, 10 point digital output, and 3 modules can be extended.

The data can be saved for up to 10 years without battery support.

It has two communication interfaces, supporting PPI and free port communication protocol.

Communication program with transducer:

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