the book of (PLC SCADA) dosing system by HMI

Introduction 1.1Mechatronics definition Mechatronics is the combination of mechanical engineering , electronic engineering , computer engineering . Software engineering , Control engineering , and system design engineering in order to design , and manufacture useful products . Originally , mechatronics just included the combination between mechanics and electronics , hence the word is only combination between mechanics and electronics. Fig() 1.2 Mechatronics Applications:  Machine vision  Automation and robotics  Servomechanics  Sensing and control system  Expert systems  Industrial goods3  Microcontrollers PLC’s  Medical mechatronics , medical imaging systems  Structural dynamic systems  Transportation and vehicular systems  Mechatronics as the new language of the automobile  Diagnostic , reliability and control system techniques 1.3 Control systems Interconnection of components forming system configuration which will provide a desired system response as time progresses . the key characteristic of control is to interfere , to influence : 1.3.1 Functions of a Control System: 1. Measurement: This is essentially an estimate or appraisal of the process being controlled by the system 2. Comparison: This is an examination of the likeness of the measured values and the desired values 3. Computation : This is a calculated judgment that indicates how much the measured value and the desired values differ and what action and how much should be taken. 4. Correction :This is ultimately the materilisation of the order for the adjustment . 1.3.2 Hardware of a Control System : Examining the automatic control system, it is found that it contains the following hardware  Sensor : a piece of equipment to measure system variables. It serves as the signal source in automatic control  Controller : a piece of equipment to perform the functions of comparison and computation  Control Element : a piece of equipment to perform the control action or to exert direct influence on the process 1.3.3 Software of a Control System: Associated with a control system are a number of different types of variables.4 First we have the Controlled Variable. This is the basic process value being regulated by the system. It is the one variable that we are specially interested in the outlet water temperature in the example above. In feedback control the controlled variable is usually the measured variable. An important concept related to the controlled variable is the Setpoint. This is the predetermined desired value for the controlled variable. The objective of the control system is to regulate the controlled variable at its setpoint. To achieve the control objective there must be one or more variables we can alter or adjust. These are called the Manipulated VariablesConclusively, in the control system we adjust the manipulated variable to maintain the controlled variable at its setpoint. This meets the requirement of keeping the stability of the process and suppressing the influence of disturbances. 1.4 Motivation to our project: The main factor at dosing of components and micro components, which defines the quality of the dosing process, is the exactness of measurement the weight by the electronic machines Dosing of materials from set of main silos to weighing containers placed in various location of a plant; bulk and fine dosing; automation of liquid dosing processes; possibility of applying a system algorithm for dosing random liquid substances dosed in a forced way. This project is suitable for many industrial applications in which costeffective weight measurements have to be performed with little engineering overhead. This set is particularly suitable if additionally automated logging functions are required in the framework of the measurement5 1.5 Aim of the Project: 1 Studying the system and estimating its problems . 2 Studying the performance of the system . 3Studying the dosing and mixing control system using PLC HMI 4Applying simulation programs on the system for studying the positives negatives of design 5Redesign and rebuild the system based on the mechatronics application.6 Chapter Two Project description7 Introduction In this chapter we will talk about our project objectives ,components and how to reach to our objective by using these components 2.1 Project description 2.1 System description Fig(21)8 2.2 system description: The system consists of two stages (mixing process and dosing process) The first stage is mixing process which three liquids are poured from three different tanks in specific percentages and specific weight by the operator using HMI touch screen into mixing tank . Then the mixing process takes a place for a specific period of time At the second stage : The conveyor runs under the mixer vertically with the mixer solenoid valve and the proximity sensor works as a detector for the empty product container under the mixer solenoid valve to dose it. For accuracy assurance of the process the container has weighted within the dosing process by loading it on a load cell lifted by double acting cylinder which is controlled by pneumatic solenoid valve and the dosing starts until getting to the required value of the product which the operator was entered by HMI touch screen. The load cell works as a weight sensor which gives a feedback of the current product weight. Then , by getting to the required weight the mixer solenoid valve is closed the pneumatic solenoid valve brings the load cell down and the dosed container on the conveyor which moves it to make the system ready for the next dosing process . The other function of the proximity sensor is to count the number of the products 2.3 Power supply PS 307; 5 A power supply module: 2.2.1 Properties of the PS 307; 5 A power supply module: ● Output current 5 A ● Output voltage 24 VDC; short circuitproof, open circuitproof ● Connection to singlephase AC mains (rated input voltage 120230 VAC, 5060 Hz) ● Safety isolation to EN 60 950 ● May be used as load power supply

Chapter One

Introduction

Introduction 1.1Mechatronics definition

Mechatronics is the combination of mechanical engineering ,

electronic engineering , computer engineering Software engineering , Control engineering , and system design engineering in order to design , and manufacture useful products Originally , mechatronics just included the combination between mechanics and electronics , hence the word is only combination between mechanics and

 Microcontrollers / PLC’s

 Medical mechatronics , medical imaging systems

 Structural dynamic systems

 Transportation and vehicular systems

 Mechatronics as the new language of the automobile

 Diagnostic , reliability and control system techniques

1.3 Control systems

Interconnection of components forming system configuration which will provide a desired system response as time progresses the key characteristic of control is to interfere , to influence :

Functions of a Control System:

1.3.1

1 Measurement: This is essentially an estimate or appraisal of the process being controlled by the system

2 Comparison: This is an examination of the likeness of the

measured values and the desired values

3 Computation : This is a calculated judgment that indicates how much the measured value and the desired values differ and what action and how much should be taken

4 Correction :This is ultimately the materilisation of the order for the adjustment

ardware of a Control System : 1.3.2 H

Examining the automatic control system, it is found that it contains the following hardware

 Sensor : a piece of equipment to measure system variables It serves as the signal source in automatic control

 Controller : a piece of equipment to perform the functions of

comparison and computation

 Control Element : a piece of equipment to perform the control action

or to exert direct influence on the process

1.3.3 Software of a Control System:

Associated with a control system are a number of different types of variables

First we have the Controlled Variable This is the basic process value being regulated by the system It is the one variable that we are

specially interested in - the outlet water temperature in the example above In feedback control the controlled variable is usually the

variable at its setpoint To achieve the control objective there must

be one or more variables we can alter or adjust These are called the Manipulated

VariablesConclusively, in the control system we adjust the

manipulated variable to maintain the controlled variable at its

setpoint This meets the requirement of keeping the stability of the process and suppressing the influence of disturbances

Motivation to our project:

1.4

The main factor at dosing of components and micro components, which defines the quality of the dosing process, is the exactness of measurement the weight by the electronic machines

Dosing of materials from set of main silos to weighing containers placed in various location of a plant; bulk and fine dosing; automation

of liquid dosing processes; possibility of applying a system algorithm for dosing random liquid substances dosed in a forced way This project is suitable for many industrial applications in which cost-

effective weight measurements have to be performed with little

engineering overhead This set is particularly suitable if additionally automated logging functions are required in the framework of the measurement

1.5 Aim of the Project:

1- Studying the system and estimating its problems

2- Studying the performance of the system

3-Studying the dosing and mixing control system using PLC & HMI 4-Applying simulation programs on the system for studying the

positives & negatives of design

5-Redesign and rebuild the system based on the mechatronics application

Chapter Two

Project description

2.2 system description:

The system consists of two stages (mixing process and dosing process) The first stage is mixing process which three liquids are poured from three different tanks in specific percentages and specific weight by the operator using HMI touch screen into mixing tank Then the mixing process takes a place for a specific period of time

At the second stage : The conveyor runs under the mixer vertically with the mixer solenoid valve and the proximity sensor works as a detector for the empty product container under the mixer solenoid valve to dose it

For accuracy assurance of the process the container has weighted within the dosing process by loading it on a load cell lifted by double acting cylinder which is controlled by pneumatic solenoid valve and the dosing starts until getting to the required value of the product which the operator was entered

by HMI touch screen The load cell works as a weight sensor which gives a feedback of the current product weight

Then , by getting to the required weight the mixer solenoid valve is closed the pneumatic solenoid valve brings the load cell down and the dosed

container on the conveyor which moves it to make the system ready for the next dosing process

The other function of the proximity sensor is to count the number of

the products

5 A power supply

;

PS 307 [

● Output voltage 24 VDC; short circuit-proof, open circuit-proof

● Connection to singlephase AC mains

(rated input voltage 120/230 VAC, 50/60 Hz)

● Safety isolation to EN 60 950

● May be used as load power supply

[Human Mahcine Interface] : HMI

HMI Usage:

• Archiving process values and alarms

• Process values and alarms logging

Process and machine parameter management

2.5.2 Siemens HMI Family

6 2.

Fig(2-5)

Detection method

Response

time

OutputOperating

voltage

Detection distance

Model

no

Statuemethod

diffusetype

<2 msNo+Nc

NPN

Dc 10-30v

10 cmG18-

3A10NC

: Relay

8

2.

Fig(2-7)

Fig(2-8) Fig(2-9)

2.8.1specification

 RELAY, 3PCO, 10A, 24VDC, PLUGIN

 Product Range: FINDER - 60 Series

 Coil Voltage: 24VDC

 Contact Current: 10A

 Contact Voltage VAC: 250V

 Contact Voltage VDC: -

 Contact Configuration: 3PDT

 Coil Resistance: 445ohm

 Relay Mounting: Quick Connect

 SVHC: No SVHC (16-Dec-2013)

 Approval Bodies: BEAB, BSI, CSA, DEMKO, IMQ, RINA, SEMKO, SETI, UL, VDE

 Coil Current: 53.9mA

 Coil Operating Lower Percent Limit: 80%

 Coil Operating Upper Percent Limit: 110%

 Coil Type: DC

 Coil Voltage VDC Nom: 24V

 Contact Current AC Max: 10A

 Contact Current DC Max: 10A

 Contact Current Max: 20A

 Contact Voltage AC Max: 250V

 Contact Voltage AC Nom: 250V

 DC Coil Power: 1.3W

 Dielectric Strength VDC: 2000V

 External Depth: 36.2mm

 External Height: 51mm

 External Length / Height: 51mm

 External Width: 32.5mm

 Mounting Type: Plug-In

 No of Poles: 3

 Nom Operating Power: 1.3W

 Operating Temperature Max: 70°C

 Operating Temperature Min: -40°C

Fig(2-10)

Principle of operation, based on the example of a loaded bending beam load cell

For each load cell, at least four strain gauges are connected together

as a complete Wheatstone bridge The stretched or compressed strain gauges are connected in such a manner that the positive or negative resistance changes are summed to produce an overall

imbalance of the bridge

The supply voltage is applied across one diagonal of the bridge and,

in the case of the sixwire connection method, also the sensor voltage SENSE The measured voltage is tapped across the other diagonal For a constant supply voltage EXC, therefore, the measured

voltage SIG changes proportionally to the introduced load In

practice, load cells contain additional resistors for temperature

compensation and for zero-signal and characteristic-value

compensation

Depending on their type and the requirements, these resistors can

be arranged at the input or output of the load cell

Fig(2-11)

: 440 ICROMASTER

The micromaster is a combination between a processor (cpu) ,

rectifier and the driver circuit

The programming language for the cpu is the parameters that is being downloaded to the inverter via basic operation panel (bop) or

by the starter software from the computer each parameter depend

on others to achieve the required task

1) Serial communication rs232 module

2) Profibus module

.2 Micromaster 440 specifications:

10

2.

Fig(2-13)

Setting the inverter to frequency supply:

2.10.3

Power terminals layout:

Input supply voltage

220 v ac

Output terminals 380v

4 Connection between the motor and mm440:

2.10.5 Basic commissioning (getting started):-

1)Reading Motor Name Plates

The parameters of the motor should be set :

: cable ROFIBUS

PROFIBUS is neither Industrial Ethernet

standard forPROFINET

to

: ROFIBUS Networks

immunity to electromagnetic interference resulting in high data

integrity To achieve this degree of immunity,

certain guidelines must

be adhered to when configuring electrical network

: arameters

2.The required number of nodes

3 The type of network components required (bus terminals, bus connectors connecting cables)

4 The LAN cables to be used

5 The required segment lengths

6 The electromagnetic and mechanical environment of the cabling (for example surge voltage protection, cable route surge voltage protection, cable route)

7.The number of RS-485 repeaters between any two DTEs is limited

to a maximum of 9

8.Increasing the overall span of a network by using repeaters can lead to longer transmission times that may need to be taken into account when configuring the network

Use in a networked system

Data is transmitted and received on pins 2 and 3 respectively

Data Set Ready (DSR) is an indication from the Data Set (i.e., the modem or DSU/CSU) that it is on Similarly, DTR indicates to the Data Set that the DTE is on Data Carrier Detect (DCD) indicates that

a good carrier is being received from the remote modem

Pins 4 RTS (Request To Send - from the transmitting computer) and

5 CTS (Clear To Send - from the Data set) are used to control In most Asynchronous situations, RTS and CTS are constantly on

throughout the communication session However where the DTE is connected to a multipoint line, RTS is used to turn carrier on the modem on and off On a multipoint line, it's imperative that only one station is transmitting at a time (because they share the return phone pair) When a station wants to transmit, it raises RTS The modem turns on carrier, typically waits a few milliseconds for carrier to

stabilize, and then raises CTS The DTE transmits when it sees CTS

up When the station has finished its transmission, it drops RTS and the modem drops CTS and carrier together

Clock signals (pins 15, 17, & 24) are only used for synchronous

communications The modem or DSU extracts the clock from the data stream and provides a steady clock signal to the DTE Note that the transmit and receive clock signals do not have to be the same, or even at the same baud rate

Note: Transmit and receive leads (2 or 3) can be reversed depending

on the use of the equipment - DCE Data Communications Equipment

or a DTE Data Terminal Equipment

unction 1 F

3

2.1

The SIMATIC PC Adapter USB connects a PC to the MPI/DP

interface of an S7/M7/C7 system via USB

A slot is not required in the

PC, which means that the adapter can also be used for

non-expandable PCs such as notebook

Fig(2-18)

2.14 Solenoid valve:

2.14.1 Solenoid valves operational principle:

A-Input sideB-DiaphragmC-Pressure chamberD-Pressure relief conduitE-Solenoid

3/4" BSP Male Inlet Port Size

11.5mm hose tail outlet Outlet Size/Type

90° angle flow Flow Direction

Universal Fitting Installation

230vAC 50Hz _ 6w Voltage

300 - SIMATIC S7

5

2.1

SIMATIC S7-300: The modular controller for innovative system solutions in the manufacturing industry SIMATIC S7-300 is the best-

selling controller of the Totally Integrated Automation spectrum with a

host of successful reference applications worldwide from the most varied industrial sectors, such as:

• Manufacturing engineering

• Automotive industry

• General machine construction

• Special-purpose machine manufacturing

• Standard mechanical equipment manufacture, OEMs

■ The ability to integrate powerful CPUs with Industrial

Ethernet/PROFINET interface, integrated technological functions, or fail-safe designs make additional investments unnecessary

■ The S7-300 can be set up in a modular configuration without the need for slot rules for I/O modules There is a wide range of modules available both for the centralized and the distributed

configuration with ET200M

■ The Micro Memory Card as a data and program memory

makes a backup battery superfluous and saves maintenance costs

In addition, an associated project, including symbols and comments, can be stored on this memory card to facilitate service calls

■ The Micro Memory Card also enables simple program or

firmware updates without a programming device

The Micro Memory Card can also be used during operation for

storing and accessing data, e.g for measured value archiving or recipe processing

■ In addition to standard automation, safety technology and motion control can also be integrated in an S7-300

■ Many of the S7-300 components are also available in a

SIPLUS extreme version for extreme environmental conditions, e.g extended temperature range (-40/-25 … +60/+70 °C) and for use where there is corrosive atmosphere/condensation

: 2DP - CPU 314C

6

2.1

The layout

(1) For setting the line voltage

(7) Clamp for strain relief

(8) Power supply ON/OFF

Chapter Three

Mechanical Design and

Construction

3.1

: Introduction

3.1.1

Our Component Dosing Using Weighing Control has been created as

an answer to market demand for precise and accurate batching of products Our dosing system is combined with external automatic systems and mechanical part The most suitable and effective

mechanics for our application is material handling

hat Is Material Handling?

3.1.2 W

The Material Handling Institute of America offers the following as one definition of material handling: “Material handling is the art and science associated with providing the right materials to the right

place in the right quantities, in the right condition, in the right

sequence, in the right orientation, at the right time, at the right cost using the right methods.”

hat Are the Major Objectives of Conveyor

3.1.3 W

Application?

Conveyors, as with all material handling equipment, do not add value

to the parts, products, or pieces that are being moved They do not shape, form, process, or change a product in any way They are totally processes of service and as a service they have an indirect bearing on product cost as part of the overhead The following is a list of some of the major objectives of implementing conveyors:

 Reduce actual manual handling to a minimum

 Perform all handling operations at the lowest reasonable cost

 Eliminate as many manual operations as possible

 Ease the workload of all operators

 Improve ergonomic considerations for each operator

 Improve workflow between operations

 Provide routing options for intelligent workflow

 Increase throughput

 Carry product where it would be unsafe to do so manually