Abstract: In order to meet the sales demonstration of asphalt concrete mixing equipment and the company's technical training needs, the development of the supporting simulation demonstration system is very important. The simulation demonstration system based on VIPA 500S PLC adopts PLC and computer integration technology, introduces new automation products, and simulates the reproduction of asphalt. Mixing station industrial production site conditions. The system has been successfully applied in the sales and training business of asphalt concrete mixing equipment manufacturer Beijing Deji.
Based on the VIPA 500S PLC, the simulation demonstration system adopts PLC and computer integration technology, and the following: Abstract: For satisfying the requirement of asphalt mix plant sale displays and company technique training, so it is imperative to develop a complete set of simulation demonstration system, The automatization new production to simulate the production work condition of the asphalt mix plant. The system is already successfully applied in the sale and training businesses of the factory, Beijing D&G Machinery, with manufacturing the asphalt mix plant.
Keywords: asphalt concrete mixing equipment PLC board CPU simulation demonstration system
Key words: asphalt mixing plant PLC computer card CPU simulation demonstration system1 Introduction
Asphalt concrete mixing equipment is an important supporting construction equipment for the road construction industry. The equipment is complicated and bulky. Whether it is from the skill training of technical personnel of production companies or the perception of equipment from construction units, a simple slide show and text The description can no longer meet the demand. Asphalt concrete mixing equipment simulation demonstration system is produced under this background. Different asphalt concrete mixing equipment manufacturers will have different requirements for the design requirements of the simulation demonstration system due to different product development concepts. The main functions to be achieved are still the same, and the automation technology and products on which the analog demonstration system depends are still connected. The automation products currently used to realize the simulation demonstration system mainly include programmable controllers, touch screens (HMI), computers and related equipment. Programming and configuration software. Based on the VIPA 500S PLC, the PLC on which the asphalt concrete mixing equipment simulation demonstration system relies depends on the integration of the PLC and the entire hardware system. This integrated design is the first time that the simulation demonstration system has been used. Attempt is also the first of the VIPA 500S PLCs after launch Second application.
2 system working principle and hardware components
2.1 System Operation
The simulation demonstration system is not under the premise of other low-voltage electrical equipment to build the control circuit, mainly by the computer, HMI, PLC three parts through MPI, serial port, Ethernet communication protocol to communicate with each other, exchange data to achieve simulation demonstration industrial production site operations.
2.2 Hardware Composition
According to the status quo of the current control system of the asphalt concrete mixing equipment industry, the hardware composition of the simulation demonstration system can basically be expressed by the following figure. The extension of the new function is only required to be attached to the bus. The figure is based on the Beijing Deji asphalt mixing equipment control system. Blueprint made simulation demonstration system hardware composition diagram.
Figure 1 hardware composition of the simulation demonstration system
2.2.1 Computer System
Including computer hosts, monitors, printers, which computer host can be commercial machine, but also for the industrial control computer. Given the IPC has a strong degree of protection, such as high seismic, anti-jamming and other functions, the industrial site more use. Simulation demonstration system system is placed in the laboratory, so you can also consider commercial brand machine. According to the actual situation of simulation demonstration system resource occupation, computer core configuration such as CPU and general market configuration with the market, which leaves a large room for expansion, such as the introduction of Video control, remote monitoring and other functions, the addition of these functions have higher requirements on the CPU and memory.
Display according to the actual needs of the industrial site configuration, the current popular single and double display mode. Multi-display mode in the asphalt mixing equipment industry is not many. Double display configuration is intuitive, simple, the configuration mode in the industry widely used, described in this article The analog demonstration system uses double display mode.
2.2.2 Human Machine Interface (HMI) System
The HMI was originally used as an alternative to the traditional buttons and lights. It has expanded the functions of printing, alarming, reporting, etc. It is now playing an irreplaceable role in industrial automation control. In asphalt concrete mixing equipment control systems, HMI is more as a redundant control system. That is, the HMI system is relatively independent. It is a standby system of the computer control system. According to the different requirements of the asphalt mixing process control, the HMI selection standard is not the same. The industry control requirements are nothing more than Production operation, status display, data setting, etc. With the intelligent and humanized development of the asphalt mixing equipment control system, video and data processing functions have also begun to be applied to field control.
2.2.3 Programmable Controller (PLC)
The PLC used in the simulation demo system is different from the PLC used in the industrial field equipment. It is mainly selected from the control function. The simulation demo system described in this article is selected by the German VIPA 500S PLC. The exact speaking VIPA 500 is a new type. The board-type CPU, which needs to be plugged into the computer's main board, is connected via the DP/MPI communication protocol and an external communication module such as DP353 to realize the entire configuration. Because the analog demonstration system does not require actual control of external devices, Therefore, we only use the VIPA 500 CPU without any external modules. This design mode greatly simplifies the external hardware circuit of the analog demonstration system.
2.2.4 Others
The SMS module and the video module are introduced as new things into the control system of the asphalt concrete mixing equipment. The short message module includes a short message exchange module and a mobile communication card (mobile number card); the video module is very simple, and an ordinary video is selected according to the video capture requirements. Camera can be.
2.3 Software Composition
2.3.1 Computer Operating System
According to the configuration software installation and programming software installation requirements Chinese WIN 2000 operating system is selected. Version is WIN2000 professional SP2 or later
2.3.2 PLC programming software
Because the host control system corresponding to the simulation demonstration system of this article is mostly SIEMENS low voltage and automation products, the program development cycle is considered when selecting the simulation demonstration system PLC. At the same time, VIPA PLC.VIPA PLC and SIEMENS PLC are selected according to the cost performance ratio. Software and hardware are fully compatible, so program development software still uses STEP 7.
2.3.3 PC Configuration Development Software
The simulation demonstration system discussed in this article corresponds to the PC configuration software Fameview 7.0
2.3.4 HMI Configuration Development Software
The Schneider XBTGT 5000 product used in the simulation demonstration system HMI product corresponds to the configuration development software Vijeo-Designer
3 Programming
3.1 Hardware Configuration
As shown in Fig. 2, this configuration is realized by STEP 7 configuration. It can be seen from the figure that the hardware configuration only adds CPU 318-2 and component CP343-1. The DP300 communication module mounted on the bus is There is no application in this project. It can be seen from the figure that there is a certain difference between the VIPA 500 hardware configuration and the ordinary Siemens hardware configuration. The following sub-items are explained.
The compatibility between VIPA PLC and Siemens PLC software and hardware is relatively speaking. It is interchangeable between I/O modules and VIPA and Siemens. However, there are certain rules for software configuration. Because of the reason of PLC hardware design VIPA 500S Series PLC CPU in hardware group
Figure 2 Hardware configuration
The state corresponds to the Siemens S7-300 series CPU 318-2. Double-click the MPI/DP item to set the MPI address to 2. This address can be freely set, but it cannot be the same as the address of the MPI communication partner.
VIPA 500S card-type CPU in the concept we can use it as an Ethernet card, PC configuration and 500S communication through the Ethernet communication protocol Unicom. As a network, each site's Web site must be set. Double-click The CP343-1 component in the hardware configuration screen pops up the network setup screen shown in Figure 3. All we need to do is add an "ETHERNET" in the subnet area, then fill in the IP address and subnet mask. IP in the figure The address is set to 192.168.201.3
After the IP address of the PLC is set, the IP address of the computer needs to be set. The setting method is to double-click the local connection and enter the Local Connection Properties dialog box as shown in Figure 4. Double-click the "Internet Protocol (TCP/IP)" in the dialog box that pops up Select Manually enter the IP address and subnet mask. In this section
Figure 3 CP 343-1 parameter settings
Figure 4 Local Network Properties Settings
The IP address of the system is set to 192.168.201.2
To this hardware configuration is basically completed.
3.2 Analog Demonstration Program Design
The PLC program design of asphalt concrete mixing equipment with redundant control is generally divided into two parts. Corresponding to the simulation demonstration system discussed in this paper, it is divided into computer control and automatic control. Here we use automatic control as an example to illustrate the programming process.
3.2.1 Motor Start Simulation Program Design
In the motor startup program design, the contactor contact interlock condition is generally added, and the VIPA 500 has no I/O module configuration, so the external input point cannot be accessed. In order to realize the analog start of the motor, the program design can be realized by connecting the original contactor contact in parallel with the internal M relay. For example, the corresponding input variable for the industrial air compressor startup is I20.0, and the corresponding data block is DB10.DBX0. 0. Add the internal relay M100.0 in the simulation start-up part of the S7 program for the hollow compressor. Then just connect the M100.0 and I20.0 in parallel to realize the correspondence between M100.0 and DB10.DBX0.0. Pictured.
3.2.2 Production Measurement Simulation Program Design
Production metering simulation is the key to the entire simulation demonstration system. This part of the program cannot be modified on the source program, so it needs to be reprogrammed. In order to maintain the clarity of the original program structure, an FC function can be added to the original project program. This function is called in the main program OB1 to realize the output of the analog weighing signal.
The output of the weighing analog signal is divided into four types in the demonstration system, including: aggregate weighing signal, powder weighing signal, asphalt scale signal, additive weighing signal. The aggregates were subdivided into 6 types, powders were subdivided into 3 types, asphalt was divided into 2 types, and additives were classified into one. As the requirements for highway construction continue to increase, there may be simulations of five or more scales.
The weighing analog signal can be adjusted according to the production parameters such as weighing time, discharge time, weighing error, etc. It is necessary to avoid frequent occurrence of certain material metering error or metering overtime in the production.
In the emergency stop, there will be storage in the scale, so the emptying of the scale needs to be realized by the HMI configuration button. The configuration of the button is determined by the call of the button triggered variable in the program. The button corresponding variable can be reset for the entire metering program, or it can be reset individually for a certain material, such as aggregate scale. The simulation demo system described in this article added a “PLC reset†button during HMI configuration. This button resets the true PLC.
3.2.3 Simulated Design of Burner Control
VIPA 500 PLC-based simulation demonstration system can realize throttle opening control such as blower door and inducer door opening and closing when simulating burner control. The opening percentage value increases and decreases as the damper opens and closes. The temperature of the inlet and outlet of the dust collector and the temperature of the chute vary with the ratio of the damper opening. At the same time, the negative pressure in the drying cylinder and the pressure difference in the dust collector also change according to a certain functional relationship.
4 upper computer monitoring configuration design
PC monitoring configuration design is divided into PC monitoring configuration design and HMI monitoring configuration design.
4.1 PC monitoring configuration design
PC monitoring configuration design can be achieved in two ways, the first, independent monitoring configuration design. That is, full use of the function functions provided by the configuration software, to achieve secondary development, in order to achieve simulation results. Fameview configuration software supports Vbscript script functions, Vbscript script functions support the implementation of more than 71 kinds of functions, including screen performance, database operations, report output, and so on. It can simulate the industrial field production process to the maximum extent, suitable for customer demonstration.
The second mode is based on the VIPA 500 PLC, that is, the host computer and the PLC realize monitoring and configuration simulation through communication. The program design in the previous Chapter 3 takes this configuration into consideration. This configuration can be used for a large number of practical applications of asphalt concrete mixing equipment in the industrial design, with only minor modifications.
SMS configuration. Short message service as part of intelligent production, in the asphalt mixing control industry began to emerge. From the analog presentation hardware composition diagram can be seen, the principle of short message service is to send short messages to the SMS processing module through the mobile phone (equivalent to Another mobile phone), the short message processing module communicates with the upper PC via the serial port and feeds the information to be processed back to the mobile phone that sent the short message.
Short message in the upper computer configuration content is first select the communication method, transmission rate setting and SMS service center number settings. As shown in the figure below, where the serial port we choose COM1, the default baud rate is 38400, SMS center number in different regions Different, you can consult the local operator.
The second step of the SMS configuration is to configure the SMS content. The SMS content can be current production data such as current production, current asphalt temperature, etc. The SMS content can also be historical production data, such as output or temperature of the past day, motor current. Values, etc.
4.2 HMI Configuration Design
HMI configuration and design are different due to HMI hardware performance. Take Schneider XBTGT as an example. Because of the limited function of HMI configuration software, the configuration of this model must be based on VIPA 500 PLC. Compared with PC configuration, HMI configuration is simpler. , just added a few external production control buttons, such as "start production", "stop production", "PLC reset", etc.
HMI video applications are relatively new. The application breaks the traditional video control mode. Traditional video applications require multiple monitors and video switches. However, HMIs are not needed. All that is needed is to set several video frames. You can. As shown below:
Figure 5 HMI video configuration screen
In addition, HMI video can also be recorded, photographed and saved. First, the video screen is added in the configuration design. The video screen shown in FIG. 5 is a single window single screen type, and multiple screens can also be displayed in a single window. This can be set as needed. .
The storage path of video and image files needs to be set during configuration and design. XBTGT with video support has an external memory card, video, and image files are saved in the memory card by default. During configuration, double-click the "Data Positioning" option of the project. , The following figure pops up the setting screen:
Figure 6 HMI data positioning settings
Set the corresponding setting of the data file option to "second drive".
5 Conclusion
VIPA 500S PLC based simulation demo system has simple hardware configuration, small software programming and configuration tasks and short development cycle. It can realize the simulation demonstration of industrial on-site production process and working conditions. The system has been sold in Beijing Deji asphalt concrete mixing equipment. Demonstration and company employees are widely used in business training.
references:
1 Fameview Configuration Software Manual
2 VIPA system 500s speed7-CPU manual 06/47
3 Schneider XBTGT Series User Manual Vijeo 4.4.0b
Author: Mu Guangya
Work unit: Beijing Deji Machinery Co., Ltd. Electronic Control Department
Address: 20 Wansheng South Street, Liyuan, Tongzhou, Beijing
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