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 electronics.
Fig()
1.2 Mechatronics Applications:
Machine vision Automation and robotics Servo-mechanics Sensing and control system Expert systems Industrial goods 2
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. 3
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 measurement
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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.
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Chapter Two Project description
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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(2-1)
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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 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 8
Fig(2-2)
2.3.1 Wiring diagram of PS 307; 5 A
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Fig(2-3)
2.4 The controller The main controller of the system is the plc type S7314C-2DP Technical specifications of CPU 314C-2DP
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2.5 HMI [Human Mahcine Interface] :
Fig (2-4) HMI stands for Human machine interface. HMI's are used as an operator control panel instead of using an excessive amount of hardware and also provides almost unlimited control and status of a fully automated machine cell.
2.5.1 HMI Usage:• Process visualization • Operator control of the process • Displaying alarms • Archiving process values and alarms • Process values and alarms logging Process and machine parameter management
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2.5.2 Siemens HMI Family
Micro Panels Mobile Panels Touch&Operaing panels Panel Pcs Pc(SCADA)
2.6 Proximity sensor :
Fig(2-5)
Model no
G183A10NC
Detection Operating distance voltage
10 cm Dc 10-30v
Output method
Statue
NPN
No+Nc
02
Response Detection time method
<2 ms diffusetype
2.7 Pneumatic cylinder
Fig (2-6)
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2.8 Relay:
Fig(2-7)
Fig(2-8)
Fig(2-9)
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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 05
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 Operating Time: 9ms Relay Type: General Purpose Release Time: 9ms Series: 60 Switched Current Max: 20A
2.9 Load cell 2.9.1 Principle of operation The basic component in each case is a special type of spring body. The application of force elastically deforms the spring body. The ohmic resistance of the strain gauges changes as a result
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. 06
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)
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2.10 MICROMASTER 440:
Fig(2-12)
2.10.1What is the micromaster? Micromaster is a type of 2p/3p motor driver called as an inverter it's supply voltage could be 220v or 380v and it drives an Ac motor which supply is 3p/2p That mean by a supply voltage of 220v a motor of 380v supply could be operated. 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 .
Parameter settings: 1) Parameters can be set using the BOP / AOP operator panels. 2) The Drive Monitor or Starter visualization programs. The driver can be connected to the pc using 08
1) Serial communication rs232 module. 2) Profibus module
2.10.2 Micromaster 440 specifications:
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Fig(2-13).
2.10.3 Setting the inverter to frequency supply:
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Power terminals layout:
Input supply voltage 220 v ac
Output terminals 380v
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2.10.4 Connection between the motor and mm440:
Controlling the micromaster via Basic Operator Panel (BOP).
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2.10.5 Basic commissioning (getting started):1)Reading Motor Name Plates
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The parameters of the motor should be set :
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2.11 ROFIBUS cable:
Fig(2-14)
PROFIBUS (Process Field Bus) is a standard for fieldbus communication in automation technology and was first promoted in 1989 byBMBF (German department of education and research) and then used by Siemens. It should not be confused with the PROFINETstandard for Industrial Ethernet. PROFIBUS is neither an openly published nor a royalty-free protocol, as opposed to MODBUS.
2.11.1ROFIBUS Networks: PROFIBUS networks were specially designed for use in an industrial environment and one of their main features is their degree of immunity to electromagnetic interference resulting in high data certain guidelines must ,integrity. To achieve this degree of immunity be adhered to when configuring electrical network 26
2.11.2 Parameters: The following parameters must be taken into account when planning an electrical network 1.The transmission rate required for the task (within a network, only one uniform transmission rate can be used) 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
2.11.3 Use in a networked system The following illustration shows the connection in a networked S7 system (MPI/DP) network containing 2 or more network nodes
Fig(2-15)
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2.12 RS232 Cable:
Fig(2-16)
RS-232 is simple, universal, well understood and supported but it has some serious shortcomings as a data interface. The standards to 256kbps or less and line lengths of 15M (50 ft) or less but today we see high speed ports on our home PC running very high speeds and with high quality cable maxim distance has increased greatly. The rule of thumb for the length a data cable depends on speed of the data, quality of the cable. 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 28
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.
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2.13 PC Adapter USB:
Fig(2-17)
The PC Adapter USB is compatible with USB V1.1 and satisfies the requirements for "Low-Powered“ USB devices. The SIMATIC PC Adapter USB supports the energy saving mode (hibernate mode)
2.13 .1 Function The SIMATIC PC Adapter USB connects a PC to the MPI/DP A slot is not required in the interface of an S7/M7/C7 system via USB PC, which means that the adapter can also be used for nonexpandable PCs such as notebook.
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Fig(2-18)
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2.14 Solenoid valve: 2.14.1 Solenoid valves operational principle:
A-Input side B-Diaphragm C-Pressure chamber D-Pressure relief conduit E-Solenoid F-Output side
Fig(2-19)
2.13.2 Specification: Type of Solenoid Valve Inlet Port Size Outlet Size/Type Flow Direction Installation Voltage
Single 3/4" BSP Male 11.5mm hose tail outlet 90° angle flow Universal Fitting 230vAC 50Hz _ 6w
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2.15 SIMATIC S7-300
SIMATIC S7-300: The modular controller for innovative system solutions in the manufacturing industry SIMATIC S7-300 is the bestselling 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 • Plastics processing • Packaging industry • Food, beverages and tobacco industries • Process engineering The SIMATIC S7-300 has been designed for innovative system solutions with the focus on manufacturing engineering, and as a universal automation system, it represents an optimal solution for applications in centralized and distributed configurations: 34
■ 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.
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2.16 CPU 314C-2DP:
The layout
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(1) For setting the line voltage (2) Mode selector (3) Mounting rail (4) Programming device with STEP 7 software (5) PG cable (6) Connecting cable (7) Clamp for strain relief (8) Power supply ON/OFF
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Chapter Three Mechanical Design and Construction
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Introduction This chapter consists of two parts .In the Mechanical part , we will talk about design of all components in our mechanical . In the electronic part, we will take a look in a load cell principal of operation , signal conditioning , calibration details , proximity , solenoid valves , relays and pneumatic
3.1 The Mechanical Part 3.1.1 Introduction: 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.
3.1.2 What Is Material Handling? 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.”
3.1.3 What Are the Major Objectives of Conveyor 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. 39
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.
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3.1.4 Types of conveyor belts According to the belt construction and target application, fabric belts are distinguished in common “conveyor belts” and highly specialized “processing belts”:
3.1.4.1 Conveyor belts The term “conveyor belt” describes belts used to convey all kinds of semi-finished and finished industrial products from one point to another. They are mainly used in the handling of unit goods both in the food and non-food production and packaging sectors and in general materials handling for storage and distribution.
3.1.4.2 Processing belts The term “processing belts” is used for belts that not only perform purely conveying functions, but also have to fulfill important functions in the actual work process. Typical examples of processing belts are: • Belts in the processing of unpacked and packed food • Printing blankets on textile printing machines • Cross lapper belts in nonwoven production • Prepress belts in particle board production • Treadmill belts, etc.
3.1.5 Belt conveyor components System components In its simplest form, a belt conveyor consists of a driving pulley (often the head pulley), a tail pulley, the tensioning device, a conveyor belt, and the supporting structure with the belt support (slider bed or carrying rollers).
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No.
Description
1 2
Driving pulley Head or tail pulley (dep. on belt running direction
3 4 5
Slider bed Carrying roller Snub pulley
6 7
Deflection roller (idler) Tension pulley (take-up pulley)
8
Carrying roller (on the return side)
9
Conveyor belt
10
Guiding pulley
Sign for driving pulley
Sign for tension pulley with tensioning direction
Belt running direction
If no additional information available the conveying system is assumed as horizontal. Many conveyor systems have additional components such as nose bars, diverters, accumulators, belt tracking elements, cleaning systems, etc.
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3.1.6 Support structure, pulley and roller fixing 3.1.6.1 Support structure The supporting structure must be rigid. It must not distort or fl ex from the forces it is subjected to, i.e. belt tension, weight of the conveyed goods, uneven floors, etc. Without a rigid structure, it would be almost impossible to track the conveyor belt by conventional means and keep it from running off under varying operating conditions (no load/partial load/full load). Furthermore, the supporting structure must be accurately aligned in all planes. Checking for squareness should preferably be done by measuring across the diagonals.
Fig(3-1)
3.1.6.2 Mounting of pulleys and rollers Normally, the driving pulley is not adjustable and as with all other pulleys and rollers, it must be aligned at right angles to the belt running axis. Adjustable bearings are recommended for head, tail, deflection and tension pulleys which are heavily loaded by the belt tensile force. As a general rule, only as many pulleys and rollers should be installed as are necessary to carry and guide the belt. Each pulley and roller can be the cause for belt running problems as well as for accumulation of debris. Slotted mounts are suitable for less heavily loaded rollers, e.g. for pivotable carrying rollers.
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a.
B
b.
3.1.6.3 Belt support Slider bed The advantages of a belt supported by means of a slider bed are primarily that the transported goods lay with greater stability on the belt, and it presents virtually no influence on belt tracking – a distinct benefit versus a similar design which employs carrying rollers. With the correctly selected belt (with appropriate running side fabric) and slider bed material it is possible to favorably influence the coefficient of friction, running noise and the belt service life. Attention is to be paid to the following points:
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• The edge of the support must be rounded and lower than the pulley surface (Δh = approx. 2 mm / 0.08 in) • The heads of mechanical fasteners must be recessed below the sliding surface • The slider bed must be precisely aligned relative to the running direction of the belt and it must be leveled so that there is no tilt (this is particularly important with slider beds of steel sheet panels), otherwise the belt will tend to run off Support by carrying rollers With long conveying distances and high overall product loads, carrying rollers can be used instead of a slider bed. In many cases, the roller bed reduces friction losses. Peripheral force and drive power requirements are proportionally reduced. Most commonly used are rollers made from precision steel tubes and roller bearings. Rollers with a plastic sheathing can also be used as they are resistant to corrosion and certain chemicals. A nonconductive synthetic cover can produce higher static charges during operation, particularly when used in conjunction with plastic bearings! Carrying rollers, in virtually all cases, have a cylindrical profile. As the conveyor belt only travels tangentially along the surface of these rollers and does not wrap around them, these rollers may have a smaller diameter than that specified for the belt’s dmin. The specified diameter must resist excessive deflection when the conveyor belt is under operational load. Attention must be paid to the following points: • The distance between the carrying rollers should be less than half the length of the transported unit loads lG, in order that the goods carried are always on at least two rollers • Carrying rollers must be accurately fitted at right angles to the belt running axis as skewed carrying rollers are frequently the cause of belt tracking problems. It is sufficient if the rollers can only be adjusted from one side, i.e. by means of slots in the supporting structure. • Pivot able carrying rollers can be installed for the purpose of guiding belt running; in these cases the pivot angle must be at least 45
± 5°. It is recommended, especially with long conveyors, that some of the carrying rollers are adjustable.
Belt support on the return side c. Drive concept i. Head drive In the case of a head-driven conveyor, the conveyor belt is said to be pulled on the carrying side. The head drive is preferred to the tail drive because of lower belt stress and smaller forces imparted to the conveyor components, i.e., pulleys and bearings.
ii. Drive units Generally the drive comprises an electric motor, a power transmission element (gearbox or belt) and the driving pulley. 46
Standardized three-phase squirrel-cage motors with star-delta start are preferable. The starting is usually smooth. The belt speed is often controlled through an electronic frequency inverter. The drive power ratings of fabric conveyor belts usually are relatively small (typically between 0.5 – 5 kW). The effective required motor power, required to move the fully loaded belt along the support structure, can easily be calculated by the CONVEY-SeleCalc program. The calculation does not include bearing drag or belt fl exion forces (particularly important in low temperature environment). iii. Power transmission The power has to be transferred from the drive to the belt. This is the function of the driving pulley. It transfers the drive force (peripheral force) from the pulley surface to the belt. In driving the fl at conveyor belt, where there is no positive engagement with the driving pulley, the power transmission capacity is dependent upon the following factors: • Arc of contact of the belt at the driving pulley • Coefficient of friction between belt and driving pulley • Contact pressure between belt and driving pulley d. Calculations of machine tape conveyor where C3 =80
By assuming of V =3 m/sec
F1= F1= 134.2*1.9 = 254.98 N 47
F2 = F1 F2 = 254.98 – 134.2 = 120.78 N
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e. Tensioning devices The required contact pressure of the conveyor belt on the driving pulley is achieved by means of a belt tensioning device. Tensioning force and resulting shaft load are lower if the tensioning device is placed on the low tension (slack) side of the driving unit. A distinction must be made between fi xed tensioning devices and constant-force tensioning devices: Fixed tensioning devices Fixed tensioning devices are to be used in installations where there is no need to compensate for variations in belt length or belt tension during operation, further for reversing operation under full load. Usually, fi xed tensioning devices are sufficient for fabric belt conveying installations, because Hebraist conveyor belts are dimensionally stable, with negligible elongation changes during startup and load changes. • A simple solution for tensioning is to use the tail pulley with a tensioning device that runs parallel to the belt's axis or the belt's running direction.
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3.1.2 Project design:
Fig(3-2)
Fig(3-3)
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Fig(3-4)
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3.2 ELECTRONIC SYSTEM: 3.2.1 LOAD CELL CALIBRATION: 1-start siwatool fta
2-On the SIWATOOL FTA interface select the interface COM1 used on your computer.
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3- Click “Online
4.
5-
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6-Before calibrating, set the “Service mode on (0)
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7-Enter the “Adjustment weight” (e.g. "051.1") and set the “Characteristic .”value range
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8-Set parameters “Min/Max weight for weighing range 0” and the “Resolution range 0” in register .”Calibration parameter 2“
9-"Resolution range 1": It is the minimum change of the displayed weight. The unit is the same as the .Weight unit” selected under the "Calibration parameter 3" tab (see below“(
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Whether the"Resolution range 1" is set to 1.0 kg the minimum change is 1 kg
10-Set parameter “Weight unit” in register “Calibration parameter 3” and .”then click “Send
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11-Ensure the scale is empty (not loaded) and click “Adjustment zero valid (3)”.-
12- Load the scale with the calibration weight 1 (the display may show a different weight value and then click “Adjustment weight 0 valid (4)
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If the corresponding weight is now changed it will be according to the actual weight and exact
.accuracy will be achieved ”(Please set “Service mode off (2) .Finally you may save the calibration data’s into a file Receive all data” from the SIWAREX FTA to the PC“ 13-save data
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3.2.1PROXIMITY:
Fig(3-5)
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3.2.2 RELAY:
Fig(3-6)
3.2.3 PNUMATIC CYLENDER
Fig(3-7)
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3.2.4 SOLENOID VALVE
Fig(3-8)
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3.2.5 PLC Wiring Diagram
Fig(3-9)
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Fig(3-10)
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Fig(3-11)
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Chapter Four Controller and software
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Introduction: In this chapter first ,we will talk about our program software flow chart of the program , Plc program , Then HMI program and how to create the program
4.1 Assigning parameters to the CPU 1. Open your project in SIMATIC Manager.A window, divided into two parts, opens with the title of your project. 2. In your project, call the configuration table HW Config. 3. Double-click on the submodule "AI5/AO". The "Properties AI5/AO2" dialog opens. 4. Disable analog output 0 by left-clicking the "Output mode" field of the "Output " tab and select "Disabled". Close the dialog with OK.Analog output 0 is enabled for controlling the motor power unit. 5. Double-click on the submodule "Positioning". The "Positioning properties" dialog opens. 6. Select "Positioning with analog output". On the drive, axis and encoder tabs, customize the properties according to your system. 7. Confirm your settings with OK.The "Positioning properties" dialog closes. 8. Save your configuration to your project with "Station > Save and compile".Your changes are now stored in your project. 9. When the CPU is in STOP, select "PLC > Load to module..." to download the configuration.The data are now downloaded from the PG to the CPU.10. Close HW Config with "Station > Close".
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You are returned to SIMATIC Manager.
4.2 Adjustment of SIWAREX FTA (step 7) : 1. Add SIWAREX FTA to the Hardware rack from the hardware list
2. click on SIWAREX FTA > right click on it > “object properties” to adjust the address
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3.adjust the address of inputs and outputs
4.Open the project > simatic 300 station > cpu 314-2cp > s7 program >blocks
5. open the OB and select open> Browse 71
6.select the CD to add the SIWAREX FTA identification code
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7. select the identification code file and the function and data blocks will be added to the project.
8. open the OB , the identification code will be shown in the ladder
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4.3 Ladder Diagram : OB1
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75
76
77
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4.4 Adjustment of Wincc program : 4.4.1 Component OF Win cc Win CC Flexible Engineering System Win CC Flexible Runtime Win CC Flexible options
Win CC Flexible Engineering System Win CC Flexible includes innovative engineering tool for the end to end configuration of all Simatic HMI devices and is available in anumber of version differentiated by price and performance thay are based on each other and are optimally tailored to individual classes of operator panel the larger software package always includes the configuration options of the smaller package: 1-simatic wincc flexible Micro Micro panel 2-simatic wincc flexible compact Such as win cc flexiblemicro and additionally Panels of the 70 series Panel of the 170 series 3-SIMATIC WINCC FLEXIBLE standard For the configuration of all somatic panels 4-simatic winccflrxible Advanced Such as wincc flexible standard and additionally simaticn Pcs,simotion,sinumerik panel pcs and standerd pcs
Win CC Flexible Runtim: The runtime software is included in the somatic HMI devices and offers different HMI functionalities and quality structures depending on the hard ware configuration of the device for pc plat forms there are Win CC Flexible Runtime versions graded according to the number of the power tags used 128,512 or 2048 power tags
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Wincc flexible options: Functional or industry-specific expansions of the engineering and runtime software are available in the form of wincc flexible . some options already integrated as standard functions in some HMI devices,while others are only available above a certain class of device.
Description : Low-priced entry-level device for basic requirements with 5.7'' STN touch screen display featuring three levels .the device can be installed landscape (horizontal) as
Design and functions: The TP 177 micro is the price-optimized version of the TP 177 A and tailored to the S7-300. PLC . it's designed for less complex HMI tasks – but thanks to its 6'' display offers and easier Operation than a 70 series panel . the option of installing the device upright (portrait orientation) creates more flexibility in the machine design The starter package is available for the TP 177 micro , which in addition to the device includes The configuration software Wincc flexible micro , the somatic HMI manual collection on DVD and MPI cable
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1.Choosing Production method screen
Ratios page, to insert the required ratios of the three main liquids (colors) to mix them.
color library page, this page contain collection of prepared colors to save operator time , and make the operation more easy. 1. Colors Ratios screen
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Insert percentage of yellow color Insert percentage of yellow color. Insert percentage of Blue color. 2. Required Weights screen
insert the required total weight of the mixture in Kg, which will fill in the mixer tank. insert the required product weight in grams.
Insert the required number of products.
Start the operation and start scada system.
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3. Prepared color screen
This page gives the operator the ability of choosing a prepared color, to save time of calculating and inserting the ratios of color. Then go to required weights.
4. Scada System screen
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Scada (supervisory control and data acquisition) system make a live connection with the plc and PCs with profibus cable.
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4.5 Flow chart of the system 4.5.1 The first stage:
Start
Choose production method From HMI
Color Library
Ratios
Insert total weight: T_W Insert product weight: P_W Insert number of products : N_P
Error MSG
YES
T_W > Mixer capacity
NO
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YES Error MSG
P_W*N _p >T_W
NO
Start Mixing process
NO
Finish Mixing
YES
END first stage
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4.5.1 The Second stage:
Start
Starting the motor
NO
Proximity ON
YES
TURN MOTOR OFF RUN THE PENUMATIC SOLENOIDE MIXER OPEN YES
NO
LOAD CELL READING= REQUIRED WEIGHT
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YES
TURN MOTOR ON CLOSE PENUMATIC VALVE SOLENOID MIXER OFF
NO
NO OF PRODUCT = REQUIRED NO
END 2ND STAGE
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Reference:
SIWAREX_FTA-en_V01 PC_Adapter_USB_e s7300_cpu_31xc_and_cpu_31x_manual_en-US_en-US hmi_wincc_v6_2_getting_started_en Quality Assurance graduation project 2010 Multi Component Dosing by Weighing Control graduation project 2011 Constant water level in reservoir graduation project 2011
http://support.automation.siemens.com https://www.automation.siemens.com/WW/forum/guests/PostS how.aspx?PageIndex=1&PostID=110356&Language=en
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Appendix
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APPENDIX A PLC SPECIFICATIONS
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APPENDIX B HMI TECHNICAL DATA
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Display
5.7 inch STN display , 4 blue mode levels
Resolution
320 x 240 or 240 x 320 pixel
Control elements
Touch screen resistive analog
User memory
256 KB
Interfaces
1 x RS485
Installation cutout
198 x 142 mm (W x H)
Front panel
212 x 156 mm (W x H)
Depth
44 mm
Configuration software
Wincc flexible compact
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APPENDIX C LOAD CELL GETTING STARTED
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SIWATOOL FTA
Types of siwarex tool: SIWAREX FTA SIWAREX U SIWAREX CS SIWAREXFTC Function The primary task of the SIWAREX FTA consists of the precise measurement of the current weight values in up to three measurement ranges and the exact control of the weighing procedure. The control of the weighing procedure is completely run from the weighing module as if in separately constructed weighing electronics. The integration in SIMATIC enables the progress of the weighing procedure to be influenced directly from the PLC program however. This enables reasonable task 97
distribution: The extremely fast weighing functions are performed in the SIWAREX module, latching and signal linking is done in the PLC There are different automatic weighing procedures for which SIWAREX FTA can be configured optimally by defining the corresponding parameters Commissioning and Service with SIWATOOL FTA: For commissioning, there is a special program SIWATOOL FTA for Windows operating systems The program enables commissioning of the scale without having to understand automation technology. During service procedures, you can analyse the processes in the scale and test them with the help of a PC. Reading the diagnostics buffer from the SIWAREX FTA is very helpful in analysing events Besides complete access to all parameters, memory or print-outs of the weighing file, the program can create weighing curves as well SIWATOOL FTA can also be used for reading the contents of the calibratable records from the calibratable scale memory
The following image shows the structure of the individual program windows
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SIWAREX
Connection areas for SIWAREX FTA The following connection areas are found on the front as Screw-in connector for 24 V power supply 40pin connector for load cell connection, digital input and output, RS 485 analog output, counter input 9pin (female) D-sub connector for RS 232 to PC or printer connection
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The SIMATIC construction guidelines apply for connecting the 40 pin connector Flexible cables with a cross-section of 0.25 to 1.5 mm can be used. Remove the insulation from the cable for 6 mm and install wire end sleeves
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Load cell connections : Sensors equipped with strain gauges and that meet the following conditions can be connected to the SIWAREX FTA Characteristic value 1.... 4 mV/V Supply voltage of 10.2 V is permitted The connection is made to the 40 pin front connector. The connection should be made using the cable described in chapter Accessories
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Technical specifications of SIWAREX FTA
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