Organic acids are important raw materials for chemical, food, and other industries. Because of their high unit value, variety of specifications, and huge investment in production, they have high requirements for automatic filling production lines. There are no such production lines in China, and they need to be imported from abroad. A few million dollars or more, therefore, domestic development can not only save foreign exchange, but also provide users with timely and convenient services, while greatly improving the level of automation of enterprise production.
System Process Description
In the organic acid automatic filling production line that I undertake, there are three kinds of product varieties for users (1#, 2#, and 3#), and there are also three types of measurement specifications for each product (A, B, and C). There will be 9 kinds of production specifications afterwards, the specification of the variety is various and make the system configuration and function more complicated. The characteristics of organic acids are: high corrosiveness, high product value, unstable density, and unstable flow rate pressure. Therefore, in the process of designing and manufacturing, in addition to the high requirements on the corrosion resistance of the materials used in the production line, the user also needs to prevent dripping during the filling process, and puts forward more stringent precision and speed requirements.
1) Filling material temperature: 5~35°C
2) Material Density: organic acid about 1.2g/cm3, organic acid salt about 1.3g/cm3
3) Material viscosity: organic acid about 50CP, organic acid salt about 150CP
4) Feed pipe inlet pressure: ≥ 0.2Mpa, fluctuation range ± 10%
5) Filling equipment layout area: 1200m2
6) The main parameters of the system are as follows, see Table 1
7) The system process is (taking line I as an example):
Empty barrel finishing - Empty barrel filling and filling station - Detection and positioning - Filling head down - Filling valve open - Start filling - Mass metering - Reach 90% (set value - compensation value) - Regulating valve rheology Small—reaches 100%×(setting value—compensation value)—filling valve is closed—vacuum adsorption—full barrel filling and filling station—steering—hanging—screw cap—labeling—stacking—winding—product output< br> functional requirements
1) The production line includes: filling line I (for 30KG filling) and filling line II (for 250KG or 1200KG filling);
2) No. 1 filling line and No. II filling line can be operated independently or simultaneously. However, the No. II filling line can only produce one specification (250 KG or 1200 KG) at a time. There are three types of operation combinations for the entire production line: I, I+II, and II; I have three filling stations (1A, 1B, 1C), and each filling station must fill three barrels at the same time. (corresponding to 3 flowmeters respectively); II line has 6 filling stations (2A, 2B, 2C, 3A, 3B, 3C), and only one filling station can be selected for work (2A among them) The flow meter shares a flow meter with the 3A station, while the 2B and 3B stations share a flowmeter...), while the 2A, 2B, and 2C (250KG specifications) are placed on the tray in groups of 4 barrels. One flow meter is used for the barrel, and the filling process is as follows: the second barrel, the third barrel, and the fourth barrel are sequentially filled after the filling of the first barrel; and each station of the 3A, 3B, and 3C (1200KG specifications) is each time Fill only one barrel;
4) Convenient data setting and display: once filling amount (65%~99%), final setting value (100%), compensation amount (prevention of overshoot, can be arbitrarily adjusted), pass judgment interval setting, pass Product count, non-conforming product count, total output (barrels), total filling volume (weight), instantaneous flow upper (lower) limit alarm setting and display;
5) For the convenience of commissioning and maintenance, a manual manual start/stop switch is assigned to each conveyor.
6) Emergency stop switches are provided on the PLC cabinet door, on-site, on each human-machine interface, etc. to facilitate the operator to park at the fastest speed in all areas of the site;
7) When the program is running, you must first select the "filling station" and then select "Automatic" to be effective, and start running, otherwise it is invalid;
8) In the conspicuous position of the workshop, set up a warning light and a "start-up preparation" sound and light prompt. The "start-up preparation" sound and light prompts start from the selection of the "filling station" until the end of the "automatic" selection, and the sound and light prompts are intermittent. Sound, alarm sound and light are continuous sounds;
9) The flowmeter includes frequency counting output (FC) and analog output (FA). The frequency output is used as the cumulative flow filling measurement, and the analog value is used as the upper and lower limit alarm of the instantaneous flow;
10) "Filling button", status and equipment fault indication are set on the man-machine interface. There are text prompts during the filling process. After the automatic filling is finished, reset the "start filling" button. During the filling process, if necessary, stop. , can press the "manual stop filling" button;
11) Anti-drip design: After filling, the viscous material remaining on the surface of the filling head will have to flow for a certain time. If it drips outside the container, it will cause pollution. This filling system uses a vacuum generator to suck back. The system ensures no leaks.
System composition and control scheme
Control system composition (see Figure 1)
The description of the control scheme is to reduce field wiring as much as possible, make the system more reasonable, complete functions, and operate more conveniently. Set up an MB+ master station at PLC1, and set up several MB+ substations at the place where the input and output equipment is concentrated on the production line. Illustration.
As the filling accuracy of the system is extremely high, if the general flow meter and analog data acquisition and calculation are adopted, the requirements for use will not be met. Therefore, in addition to the selection of mass flowmeters of internationally renowned brands as measuring instruments, Schneider QUANTUM products are also used as master controllers for data acquisition and control terminals; three high-speed counter modules (5 channels/module, 100 kHz) are configured to quickly acquire the frequency output pulses of 12 mass flow meters. The acquisition speed is fast and the hardware configuration is simple and convenient.
Higher accuracy requires stable flow. On the one hand, the high level tank is used for level and pressure adjustment to keep it in a relatively constant area. On the other hand, the analog output (4~20mA) of the mass flowmeter can be used. It is convenient to monitor the instantaneous flow in the pipeline. Once the upper and lower limits allowed by the system are exceeded, an audible and visual alarm signal will be emitted, and secondary adjustments will be made.
In order to facilitate the user to modify the data variables in the scene, there are three MAGELIS man-machine interfaces on site; OP1 and OP2 screens can both operate and display the entire production line; OP1 is mainly used to set and display the 30KG filling line. Work station selection" and "primary filling amount" (ie, about 90% of the final filling volume, which can be arbitrarily modified), "final filling volume" (100%), "compensation amount" (prevention of overshoot) , Qualification determination interval setting, qualified product count, unqualified product count, total output (barrels), total filling volume (weight), instantaneous flow upper (lower) limit alarm setting and display; OP2 is mainly used to set Display data of 250KG/1200KG bottling line and the rest with OP1; OP3 is used for data setting display of labeling equipment, and can modify and display label data such as category, batch number, production date, expiration date, weight, etc. ;
1) The central control room PC1 monitors the entire production line and key parts of the site in real time;
2) PLC1 is a QUANTUM-PLC product, and PLC2 is a MOMENTUM-I/O substrate;
3) The configuration of PLC1 is (64DI, 128DO, 12HSC, 12AI). A 10.4" man-machine interface is connected through the MB port on the CPU. At the same time, the CPU is also divided by MB+ port and MOMENTUM station (Substation 2, 32DI; substation) 3, 32DO; substation 4, 32DO; substation 5, 32DO) and another 10.4" man-machine interface (substation 6) for connection;
4) Configure a 16-point analog input module on PLC1 to monitor instantaneous flow;
5) Configure three high-speed counting modules on PLC1 for flow measurement, each module includes 5 measurement channels;
6) PLC 1_QUANTUM hardware configuration and address definitions are shown in Table 3;
7) Table 4 shows the hardware configuration and address definition of MB+ stations;
System Process Description
In the organic acid automatic filling production line that I undertake, there are three kinds of product varieties for users (1#, 2#, and 3#), and there are also three types of measurement specifications for each product (A, B, and C). There will be 9 kinds of production specifications afterwards, the specification of the variety is various and make the system configuration and function more complicated. The characteristics of organic acids are: high corrosiveness, high product value, unstable density, and unstable flow rate pressure. Therefore, in the process of designing and manufacturing, in addition to the high requirements on the corrosion resistance of the materials used in the production line, the user also needs to prevent dripping during the filling process, and puts forward more stringent precision and speed requirements.
1) Filling material temperature: 5~35°C
2) Material Density: organic acid about 1.2g/cm3, organic acid salt about 1.3g/cm3
3) Material viscosity: organic acid about 50CP, organic acid salt about 150CP
4) Feed pipe inlet pressure: ≥ 0.2Mpa, fluctuation range ± 10%
5) Filling equipment layout area: 1200m2
6) The main parameters of the system are as follows, see Table 1
7) The system process is (taking line I as an example):
Empty barrel finishing - Empty barrel filling and filling station - Detection and positioning - Filling head down - Filling valve open - Start filling - Mass metering - Reach 90% (set value - compensation value) - Regulating valve rheology Small—reaches 100%×(setting value—compensation value)—filling valve is closed—vacuum adsorption—full barrel filling and filling station—steering—hanging—screw cap—labeling—stacking—winding—product output< br> functional requirements
1) The production line includes: filling line I (for 30KG filling) and filling line II (for 250KG or 1200KG filling);
2) No. 1 filling line and No. II filling line can be operated independently or simultaneously. However, the No. II filling line can only produce one specification (250 KG or 1200 KG) at a time. There are three types of operation combinations for the entire production line: I, I+II, and II; I have three filling stations (1A, 1B, 1C), and each filling station must fill three barrels at the same time. (corresponding to 3 flowmeters respectively); II line has 6 filling stations (2A, 2B, 2C, 3A, 3B, 3C), and only one filling station can be selected for work (2A among them) The flow meter shares a flow meter with the 3A station, while the 2B and 3B stations share a flowmeter...), while the 2A, 2B, and 2C (250KG specifications) are placed on the tray in groups of 4 barrels. One flow meter is used for the barrel, and the filling process is as follows: the second barrel, the third barrel, and the fourth barrel are sequentially filled after the filling of the first barrel; and each station of the 3A, 3B, and 3C (1200KG specifications) is each time Fill only one barrel;
Fig. 1 Composition of automatic control system
4) Convenient data setting and display: once filling amount (65%~99%), final setting value (100%), compensation amount (prevention of overshoot, can be arbitrarily adjusted), pass judgment interval setting, pass Product count, non-conforming product count, total output (barrels), total filling volume (weight), instantaneous flow upper (lower) limit alarm setting and display;
5) For the convenience of commissioning and maintenance, a manual manual start/stop switch is assigned to each conveyor.
6) Emergency stop switches are provided on the PLC cabinet door, on-site, on each human-machine interface, etc. to facilitate the operator to park at the fastest speed in all areas of the site;
7) When the program is running, you must first select the "filling station" and then select "Automatic" to be effective, and start running, otherwise it is invalid;
8) In the conspicuous position of the workshop, set up a warning light and a "start-up preparation" sound and light prompt. The "start-up preparation" sound and light prompts start from the selection of the "filling station" until the end of the "automatic" selection, and the sound and light prompts are intermittent. Sound, alarm sound and light are continuous sounds;
9) The flowmeter includes frequency counting output (FC) and analog output (FA). The frequency output is used as the cumulative flow filling measurement, and the analog value is used as the upper and lower limit alarm of the instantaneous flow;
10) "Filling button", status and equipment fault indication are set on the man-machine interface. There are text prompts during the filling process. After the automatic filling is finished, reset the "start filling" button. During the filling process, if necessary, stop. , can press the "manual stop filling" button;
11) Anti-drip design: After filling, the viscous material remaining on the surface of the filling head will have to flow for a certain time. If it drips outside the container, it will cause pollution. This filling system uses a vacuum generator to suck back. The system ensures no leaks.
System composition and control scheme
Control system composition (see Figure 1)
The description of the control scheme is to reduce field wiring as much as possible, make the system more reasonable, complete functions, and operate more conveniently. Set up an MB+ master station at PLC1, and set up several MB+ substations at the place where the input and output equipment is concentrated on the production line. Illustration.
As the filling accuracy of the system is extremely high, if the general flow meter and analog data acquisition and calculation are adopted, the requirements for use will not be met. Therefore, in addition to the selection of mass flowmeters of internationally renowned brands as measuring instruments, Schneider QUANTUM products are also used as master controllers for data acquisition and control terminals; three high-speed counter modules (5 channels/module, 100 kHz) are configured to quickly acquire the frequency output pulses of 12 mass flow meters. The acquisition speed is fast and the hardware configuration is simple and convenient.
Higher accuracy requires stable flow. On the one hand, the high level tank is used for level and pressure adjustment to keep it in a relatively constant area. On the other hand, the analog output (4~20mA) of the mass flowmeter can be used. It is convenient to monitor the instantaneous flow in the pipeline. Once the upper and lower limits allowed by the system are exceeded, an audible and visual alarm signal will be emitted, and secondary adjustments will be made.
In order to facilitate the user to modify the data variables in the scene, there are three MAGELIS man-machine interfaces on site; OP1 and OP2 screens can both operate and display the entire production line; OP1 is mainly used to set and display the 30KG filling line. Work station selection" and "primary filling amount" (ie, about 90% of the final filling volume, which can be arbitrarily modified), "final filling volume" (100%), "compensation amount" (prevention of overshoot) , Qualification determination interval setting, qualified product count, unqualified product count, total output (barrels), total filling volume (weight), instantaneous flow upper (lower) limit alarm setting and display; OP2 is mainly used to set Display data of 250KG/1200KG bottling line and the rest with OP1; OP3 is used for data setting display of labeling equipment, and can modify and display label data such as category, batch number, production date, expiration date, weight, etc. ;
1) The central control room PC1 monitors the entire production line and key parts of the site in real time;
2) PLC1 is a QUANTUM-PLC product, and PLC2 is a MOMENTUM-I/O substrate;
3) The configuration of PLC1 is (64DI, 128DO, 12HSC, 12AI). A 10.4" man-machine interface is connected through the MB port on the CPU. At the same time, the CPU is also divided by MB+ port and MOMENTUM station (Substation 2, 32DI; substation) 3, 32DO; substation 4, 32DO; substation 5, 32DO) and another 10.4" man-machine interface (substation 6) for connection;
4) Configure a 16-point analog input module on PLC1 to monitor instantaneous flow;
5) Configure three high-speed counting modules on PLC1 for flow measurement, each module includes 5 measurement channels;
6) PLC 1_QUANTUM hardware configuration and address definitions are shown in Table 3;
7) Table 4 shows the hardware configuration and address definition of MB+ stations;
Application summary
The control part of the filling system not only adopts advanced technology and stable performance of Schneider industrial control products, but also has strong support and cooperation from Schneider's related technical personnel in program design, software programming, etc. The system incorporates computer technology and programmable Control technology, data setting and display technology, bus technology, high-speed counting technology, sensor technology and software programming technology, etc., make advanced program design, reasonable hardware and software configuration, project progress is extremely smooth, all parameters meet or exceed the user acceptance The standard, especially the measurement accuracy is controlled within ±0.1% (acceptance standard is ±0.125%), and the filling speed is within 3 barrels/minute·30KG. After two months of trial operation, the system passed user acceptance at one time. Now, the production line has been operating stably for nearly a year and has been fully affirmed by users. ■(Packaging Digest China Author: Hefei General Machinery Research Institute Chen Shixiang)
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