Research and improvement of a heating oven for molds in liquid plastic tags manufacturing with scada system faculty of high quality training graduations thesis of the mechatronic engineering

INDEX LIST OF FIGURES: LIST OF TABLES: ACKNOWLEDGEMENT ABSTRACT CHAPTER 1: INTRODUCTION 1.1 Introduction 1.2 Manufacturing process of Plastic tag products 1.3 Subject and scope 1.3.1 Research subjects 1.3.2 Scope of the study 1.4 Improvement methodology CHAPTER 2: LITERATURE REVIEW 10 2.1 Concept and definition about heating ovens 10 2.1.1 Definition of heating oven 10 2.1.2 Introduction to electric oven 10 2.2 Industrial oven: 11 2.2.1 Types of Industrial Oven: 11 2.2.2 Commercially available industrial ovens 12 2.3 Thermal concepts and principles 14 2.3.1 Heat energy 14 2.3.2 The rocess of heat gain and exothermic 15 2.4 PI control temperature: 18 2.5 Methods for determining the parameters of a PI controller: 20 2.5.1 Manual adjustment method 20 2.5.2 Determining parameters for PI controller by experimental method (the second method of Ziegler - Nichols) 21 2.5.3 Method Chien - Hrones - Reswick (CHR) 21 2.5.4 Cohen - Coon method 22 2.5.5 Method Wang - Juang - Chan (WJC) 23 2.5.6 Tyreus – Luyben Method: 24 2.6 Select controller design method 24 CHAPTER 3: DESIGN AND IMPROVEMENT 26 3.1 Mechanical design: 26 3.1.1 Calculation and selecting components: 26 3.2.2 Implementation: 56 3.2 Electrical design: 59 3.2.1 Block diagram of Heating system: 59 3.2.2 Operational description: 60 3.2.3 Schematic: 60 3.2.4 Diagram of Circuit: 63 3.3 Control Design: 64  Control’s target 64 3.4 SCADA system 70 3.4.1 HMI 70 3.4.2 Factory IO 71 3.5 Set up parameters for PI controller: 71 3.5.1 System definition: 71 3.5.2 Determine PI controller parameters by Ziegler-Nichols method (for Right oven): 74 3.5.3 Determine PI controller parameters by Ziegler-Nichols method (for Right oven): 76 3.5.4 Determine the PI controller parameters by using Matlab (for Right oven): 78 3.5.5 Determine the PI controller parameters for Left oven: 81 3.5.6 Apply the PI controller to the real system: 84 CHAPTER 4: EXPERIMENTS AND ANALYSIS 86 4.1 Design experiments: 86 4.1.1 List of needs: 86 4.1.2 List of metrics: 87 4.1.3 Needs Metrics Correlation Matrix: 88 4.1.4 Product Specification: 89 4.1.5 Methods of Experiment: 91 4.2 Operation experiments: 93 4.2.1 Static test: 93 4.2.2 Dynamic test: 94 4.3 Analysis: 99 4.3.1 Static test analysis: 99 4.3.2 Dynamic test Analysis: 100 100 CHAPTER 5: CONCLUSION & DEVELOPMENT 102 5.1 Conclusion: 102 5.2 Future work: 103 References 104 LIST OF FIGURES: Figure 1: Manufactory process of plastic tag Figure 2: Promotional two layers PVC baking oven [9] 12 Figure 3: Energy-saving PVC baking oven [10] 13 Figure 4: The process of cooling and baking 16 Figure 5: Response of PV to step change of SP vs time for Kp 19 Figure 6: Response of PV to step change of SP vs time for Ki 20 Figure 7: Response of the system to Ziegler-Nichols method [4] 21 Figure 8: Response of the system when adjusting Cohen-Coon[4] 23 Figure 9: System response to the Wang-Juang-Chan method[4] 24 Figure 10: Properties of plastic material 27 Figure 11: Maysor coil [11] 28 Figure 12: LOGO! 12-24 RCE siemens 6ed1052-1md00-0ba8[13] 30 Figure 13: PT100 M6 screw thermocouple temperature sensor[14] 31 Figure 14: Temperature transmitter coil[15] 32 Figure 15: HMI screen 32 Figure 16: Expansion module for LOGO! 34 Figure 17: Analog output modules 34 Figure 18: Cylinder 35 Figure 19: Galvanized steel box[16] 36 Figure 20: Corrugated iron 37 Figure 21: Stainless steel 37 Figure 22: Aluminum 38 Figure 23: Cooling system by air [17] 38 Figure 24: Cooling system by water (using radiator) [17] 39 Figure 25: Cooling system combine cooling table and water [18] 39 Figure 26: Plumbing structure 41 Figure 27: Diaper calculation of water tank 42 Figure 28: Detail calculation diagram of the radiator 43 Figure 29: Diaper calculation of the radiator 43 Figure 30: Draft drawing 50 Figure 31: Base drawing 51 Figure 32: Left oven cover drawing 52 Figure 33: Right oven cover drawing 53 Figure 34: Water tray drawing 54 Figure 35: Overall drawing 55 Figure 36: 3D simulation 56 Figure 37: Implementation process 56 Figure 38: Overall view of the machine 57 Figure 39: The oven door 59 Figure 40: Block diagram 59 Figure 41: Power supply diagram 60 Figure 42: Oven temperature control cluster 61 Figure 43: Cylinder control cluster 62 Figure 44: Cooler cluster 63 Figure 45: Circuit wiring digram 63 Figure 46: Cylinder step diagram 64 Figure 47: Structure simulation of the furnace 65 Figure 48: Flow chart of control design 66 Figure 49: Heat control diagram 67 Figure 50: Working principle of the cooling system 68 Figure 51: Control panel 69 Figure 52: The SCADA system is displayed on HMI screen 70 Figure 53: Use Factory IO to simulation machine 71 Figure 54: System response chart, experiment, Right oven 72 Figure 55: System response chart, experiment, left oven 72 Figure 56: Accurate characteristic, Approximate characteristic [7] 73 Figure 57: System response chart with Z-N-1 75 Figure 58: System response chart with Z-N-2 75 Figure 59: The system’s oscillation response chart of right oven 76 Figure 60: Chart the system’s response with K=41, T=77 77 Figure 61: Chart the system’s response with K=41, T=667 77 Figure 62: The system’s response chart with K=21,t=67 78 Figure 63: The system’s response chart with K=20.5, T=667 78 Figure 64: Measured and simulated model output 79 Figure 65: Transfer function of right oven 79 Figure 66: Right oven system response chart, matlab 80 Figure 67: Diagram of the system 80 Figure 68: Right oven response chart using PI algorithm 80 Figure 69: System response chart with Z-N-1 82 Figure 70: Measured and simulated model output 83 Figure 71: Right oven response system chart, matlab 83 Figure 72: Diagram of the system 84 Figure 73: System response chart in experiment with PI controller right oven 84 Figure 74: System response chart in experiment with PI controller of left oven 85 Figure 75: Temperature of left oven (℃) 95 Figure 76: Temperature of right oven (℃) 95 Figure 77: Testing time to set baking time (s) 97 Figure 78: Locations of sensors- upper oven 98 Figure 79: Locations of sensors-lower oven 98 Figure 80: Heating process on water 100 Figure 81: Cooling testing 100 LIST OF TABLES: Table 1: Mission statement Table 2: Specific capacities of some substances 15 Table 3: Determining parameters for PID controller Ziegler-Nichols method 21 Table 4: Select controller according to CHR method 22 Table 5: The PID set parameter according to CHR method 22 Table 6: Control parameter of Cohen-Coon method 23 Table 7: Control parameter of Tyreus-Luyben method 24 Table 8: Specific heat of aluminum mold 26 Table 9: Conductor value [12] 30 Table 10: Thermal conductivity 36 Table 11: PI controller parameter by Ziegler-Nichols method 74 Table 12: List of needs 86 Table 13: List of metrics 87 Table 14: Correlation matrix 88 Table 15: Specification 90 Table 16: Method of experiment 92 Table 17: 1-time sampling specification data collection 92 Table 18: Controlling machine mechanical test data 93 Table 19: Electrical components test data 94 Table 20: Transporting time in km (min) 94 Table 21: Experiment to discover the optimum timing 96 Table 22: Experiment to discover the optimum timing 97 Table 23: Testing time to maintenance (hour) 97 Table 24: Table determine where the optimum temperature sensor should be placed 97 Table 25: Table determine where the optimum temperature sensor should be placed 98 Table 26: 1-time sampling specification result and comment 99 Table 27: Overall 102 ACKNOWLEDGEMENT Our team would like to thank the Ho Chi Minh City University of Technology and Education's Management Board and teachers Throughout the years, the instructors of Mechanical Engineering, Mechatronics in particular, have been devoted to teaching and imparting important information and expertise to us We would especially want to thank Mr Pham Bach Duong for his committed assistance, straight counsel, and direction throughout the project-making process We continually gain more relevant information while improving the project, but we also learn the spirit of work, the attitude of serious and successful scientific study, and these are extremely important things for We are in the process of learning We also sincerely appreciate THACH GIA CO., LTD (where the product is operated) for allowing us to borrow the equipment for research and development In the process of completing the project as well as making a project report, it is difficult to avoid errors, we eagerly await your comments and recommendations so that we may gain more experience and develop our project in the best way possible We sincerely thank you! RESEARCH, IMPROVE AND MANUFACTURE OF THERMAL OVEN MOLDING PLASTIC TAG PRODUCTS Mission statement: Project name Research, improve and manufacture mold-processing furnaces for liquid plastic-label products Product Description Heating oven is used in small and medium-sized companies, enterprises with the number of workers about 57 people Project type Product improvement base on bakery products Main business goals Provide heating furnaces for companies, enterprises need to use Producing the first heating product with Vietnamese brand Minimize competitive costs with machine brands from other countries Main marketing On online sales websites such as AMAZON, EBAY, ALIBABA Sub market Social networking sites such as Facebook, Youtube, Weibo, Zalo, Zing me, Assumptions constraints Related parties and Create products with low cost, suitable productivity, easy to repair, suitable for processing workshops to distribute to garment companies, Material suppliers (electromechanical system suppliers, control circuit systems, etc.), Assembly and processing workshops, service marketing groups, buyers and users, distributors and agents physical Table 1: Mission statement ABSTRACT Plastic manufacturing sector is a strong development trend in today's industrialized society, and it plays an essential part in human existence Although plastic has detrimental impacts on the environment and humans, we cannot ignore the numerous advantages it provides As a result, the plastics manufacturing sector, particularly the manufacture of liquid plastic logos and cards, is quickly expanding These items are frequently used as key chains, shoe tags, emblems, and souvenir presents Not only that, but it also manufactures protective equipment such as gloves, helmets, and so on Heating is a crucial stage in the manufacture of a plastic product It aids in the transformation of plastic from liquid to solid As a result, we research and improve a heating oven With characteristics such as compactness, ease of transportation, high efficiency, and cheap cost, we will strive to create the best machine, therefore making the plastic production line more effective Our country is growing in terms of modernisation and industrialisation People's lives are becoming increasingly better As a result, energy plays a role important Energy is used in a variety of ways, including the quantity of heat needed for heating, drying, and heat treatment It is critical to utilise this energy source effectively and efficiently Provides high efficiency and significant advantages to consumers as well as the entire land water system in general Electric ovens are frequently utilized in industry to satisfy a variety of practical purposes Thermal energy is used in business and everyday life Play a very vital function Drying may be heated using heat energy As a result, the logical and effective utilization of energy resources is critical Because of the answer to many practical needs, electric resistance furnaces are widely employed in industry CHAPTER 1: INTRODUCTION 1.1 Introduction Nowadays, the application of plastic stamps to serve in industries such as garments, shoes of brands is extremely rich that can be attached to many types of products that wrongly promote brands and makeup for more beautiful products A number of lines of flexible rubber labels are listed as follows: - Stamps of flexible rubber rubbers used to make brand identity logos - Stamps of plastic rubber labels used as key chains - Stamps of plastic rubber labels used in fashion and apparel industry - Stamps of plastic rubber labels for making household appliances labels - Stamps of plastic rubber labels make the team of interior labels - Stamps of plastic rubber labels for making briefcases, suitcases and bags - Stamps of plastic rubber labels for making footwear labels The market for plastic labeling machines has been largely dominated by China and the prices of Chinese products are quite high The potential of quality Vietnamese products and more reasonable prices is huge Major brands of the world are increasingly concentrated in Vietnam and their need to use labels is very large, which makes the plastic stamp market in greater demand than ever Therefore, a series of machines bearing the Vietnamese brand name are extremely necessary, they will make it easier for manufacturers to invest in producing plastic labels The research, manufacture and manufacture of one or several types of machines in the plastic label production process is necessary and practical 1.2 Manufacturing process of Plastic tag products Blending ingredients ` Taking out of mold, classifying Heating, Cooling Vacuum raw material Dripping raw material Greatly affecting the production efficiency Figure 1: Manufactory process of plastic tag 4.1.5 Methods of Experiment: METHODS OF EXPERIMENT Types of Test Specification name Unit Material of part list x In comparison to the material list Controller type list x In comparison to the controller list Weight kilo Gram x Placing the machine on the scale and reading the outcome Sampling Static Dynami c Method description Overall dimension m x Using a ruler to measure the machine's dimensions Design of mechanism list x In comparison to the mechanism list x Counting time for assembling the whole machine Assembly time day Time for cylinder go full duration cycle % x Adjust the throttle and timing, then determine if the cylinder can safely expel the mold from the oven Display screen list x In comparison to the display screen list Transportation time x Time to transport the machine from 91 company to home (6 km) Time to set baking time second Experiment with oven list Temperature in left and right oven after starting to work 30p 15 ℃ x Counting time to change baking time x Experiment to determine the optimal timing x Turn on the oven and leave it for 30 minutes before conducting trials and evaluating product quality Table 16: Method of experiment time sampling specifications: Specification name Sampling Actual Value Material of part Iron Controller type PLC LOGO!, Expansion modules, Analog output modules Sensor type RTD PT100 Design of baking mechanism Heating Coil Display screen PLC LOGO! HMI Screen Upgrade material Stainless iron mechanism Design of electric wiring Electric wiring Weight (kilogram) 51kg Overall Dimension (m) LxWxH [0.85x0.8x1.4] Number of ovens (qty) Display Screen Table 17: 1-time sampling specification data collection 92 4.2 Operation experiments: 4.2.1 Static test: a Mechanical design: The weight of the machine decides whether the machine is compact or not and the ability of transportation from one place to another In addition, together with the weight, the dimension of the outlet also decides the installing capability, the convenience of replacing and the required space that the machine demands in order to operate at full functions Ideal Marginal Measured value value value Total Weight 50kg 55kg 51kg Dimension 0.85x0.8x1.4 0.85x0.8x1.4 0.85x0.8x1.4 Table 18: Controlling machine mechanical test data NO Specifications Result (%) 80% 100% b Electrical design: We proceed to examine the electrical design after establishing that the mechanical design is satisfied In this section, we must ensure that the board contains all of the required electrical components Then we must verify that these components are put in the right locations according to the design schematic circuit If all of the tests pass, the board is ready to go on to the dynamic test No Electrical components Ideal value Marginal value Measured value Result Power supply 3 100% Thermistor 2 100% Domino 2 100% PT100 3 100% Solenoid 4 100% Heat tray 2 100% 93 Expansion module for LOGO! 1 100% PLC LOGO! 1 100% CB 1 100% 10 Contactor 1 100% 11 Transducer 2 100% 12 Relay 3 100% 13 Analog output modules 1 100% Table 19: Electrical components test data Following these tests, the machine fulfills the weight and dimension criteria, and all electrical components are properly positioned on the board in their stated locations The machine is in GOOD condition right now and is ready for the dynamic test 4.2.2 Dynamic test: After checking all of the static quantities to ensure that everything is in good working order We proceed to the following stage, which is to test each amount during the controlling process These tests are performed to determine if the controlling algorithm is good or not, as well as the capacity of the electrical design Transporting time in 6km – Dynamic test Ideal value Marginal value Test n” Measured value Results(%) 30 40 35 85.7 35 85.7 Average Table 20: Transporting time in km (min) 94 Check the stability of machine – Dynamic test : Check the stability of left oven after 30 minutes Figure 75: Temperature of left oven (℃) Check the stability of right oven after 30 minutes Figure 76: Temperature of right oven (℃) 95 Determine the best timing by experiment Left oven Right oven Test n’’ Measured value Unburnt Surface finish Elasticity Strength Results(%) (min) (min) 20 17 15 10  25 14 4  25 14 12 10 10 10  25   25  50  25  25 10  50 11 12 7 13 14        75   75   50   100 Table 21: Experiment to discover the optimum timing After some trial and error, we discovered that the best time for the mold is: +Left Oven: (min) +Right Oven: (min) Testing the accuracy of the machine and the range of time (8/2) – Dynamic test Time of left/ right oven (m) 8-2 8-2 8-2 8-2 8-2 8-2 8-2 8-2 8-2 Good product Bad product          96  8-2  8-2  8-2  8-2  8-2  8-2 Result 100% Table 22: Experiment to discover the optimum timing Testing time to set baking time – Dynamic test Figure 77: Testing time to set baking time (s) Testing time to maintenance – Dynamic test Ideal value Marginal value 1.5 Test n’’ Measured value 2h Results(%) Table 23: Testing time to maintenance (hour) Comment: Maintenance time is excessive and unsatisfactory The reason for this is because the area of the electrical box is too tiny, making it difficult to wire and replace broken equipment Determine where the optimum temperature sensor should be placed - Upper oven Position Ideal value Measured value Percentage change(%) 250 247-249 1.2-0.4 250 245-248 2-0.8 Table 24: Table determine where the optimum temperature sensor should be placed 97 Figure 78: Locations of sensors- upper oven Determine where the optimum temperature sensor should be placed - Lower oven Position Ideal value Measured value Percentage change(%) 300 297-299 0.33-1.67 300 295-297 1-1.67 300 296-298 0.67-1.33 Table 25: Table determine where the optimum temperature sensor should be placed Figure 79: Locations of sensors-lower oven Comment: The furnace's temperature in the core is the greatest, while the temperature in the outlying areas is the lowest However, all of the sites have temperature readings that are within the acceptable range As a result, the temperature sensor may be put almost anywhere 98 4.3 Analysis: 4.3.1 Static test analysis: Specification name Result (%) Material of part 100 Controller type 100 Weight 100 Overall dimension 100 Design of mechanism 100 Time for cylinder go full duration cycle 100 Display screen 100 Upgrade material 100 Time to change the new oven 100 Material of part 100 Comment The result meets most of the initial requirements of a basic heating furnace 100 % Table 26: 1-time sampling specification result and comment 99 4.3.2 Dynamic test Analysis: Figure 80: Heating process on water Figure 81: Cooling testing Comment: The cooling mechanism still works, but only partially, because returning the baking temperature to its initial degree is difficult The cooling rate increases as the temperature rises, and it progressively lowers as the temperature approaches the lower threshold 100 Specification name IR Unit Material of part List Ideal value Marginal Measured value value Controller type List Weight kilogram Overall dimension m % Match Iron 100 PLC LOGO!, 100 Expansion module, Analog output module 51 kg 100 [0.85x0.8x1.4] 100 Assembly time Day 100 Time for cylinder go full duration cycle List 100 Display screen List 100 Transportation time minute Time to set baking time second Temperature of left oven after 30 minutes ℃ Time to maintenance hour Temperature of right oven ℃ 30 40 35 85.7 100 300 309 303 99 1.5 250 257 252.4 99 101 after 30 minutes Accuracy of the machine 100 % 97 100 Average 100 91 Table 27: Overall Comment: The end result completely fits the majority of the requirements of a basic heating furnace Transporting time is 85.7%, but it is still within acceptable limits However, the maintenance time has NOT fulfilled the criteria since the electrical box is too tiny, making maintenance difficult CHAPTER 5: CONCLUSION & DEVELOPMENT 5.1 Conclusion: - Successfully design, construct, and install a mechanical system, as well as assure the machine's operational needs The closed grill design reduces heat loss and expenses while also decreasing waste heat to the environment, resulting in a more comfortable working environment for production workers - Because the heating system and the operating system are all controlled by a PLC, the system's operating program may be changed to meet the needs of the business Customize the baking time to suit each food type Assist with a variety of baking time options that are appropriate for a wide range of products - The control PI algorithm is based on the Ziegler-Nichols technique mixed with an experimental approach, achieving high stability, low overshoot, and reaction time to satisfy the furnace's operating requirements, assuring product quality assurance after baking - Automating product shutting, opening, and taking ensures worker safety and reduces manual processes - The working environment is improved thanks to the alternative design to reduce noise while the machine is operating - Cooling system works relatively quiet, easy to disassemble, clean and replace - The machine includes an easy-to-use interface and operations that are handy for the operator 102 - After 30 minutes of operation, the machine is stable and generates a high-quality product that meets the company's specifications - The maintenance time has NOT fulfilled the criteria since the electrical box is too tiny, making maintenance difficult 5.2 Future work: The heating oven for molds in liquid plastic tags may be developed in the future by the following contents: - Change the PLC controller to acquire an integrated PID algorithm, which reduces response time during furnace startup - Improving the cooling system to enhance capacity, the company's suggested water-chiller cooling system might be considered - Resize the electrical box to make it easier to maintain when necessary 103 References Book: [1] Nguyễn Thị Phương Hà, Huỳnh Thái Hòa, Lý Thuyết Điều Khiển tự động, TP.HCM: NXB Đại học Quốc Gia TP.HCM, 2005 [2] H V Bình, Tự động hóa q trình sản xuất, Trường ĐH Sư phạm Kỹ thuật TpHCM, 2004 Đ T Ba, Matlab ứng dụng kỹ thuật, TpHCM: NXB Đại học Quốc gia, 2015 N V Đạt, "Nghiên cứu, chế tạo tủ điều khiển thu hồi nhiệt điều khiển ổn định nhiệt độ lò sấy," TpHCM, 2016 N P Quang, Matlab&Simulink, Hà Nội: NXB khoa học kỹ thuật, 2005 Karl T Ulrich, Steven D Eppinger, Product design and Development, Mcgraw Hill Higher Education, 2011 V L Chương, "Process Control_Slide," Ho Chi Minh University of Teachnology and Education, Ho Chi Minh, 2020 R.V.Dukkipat, Analysis and design of control systems using matlab, New Delhi: New Age International Publishers, 2007 [3] [4] [5] [6] [7] [8] Website: [9] [10] [11] [12] [13] [14] [15] P V Trí, Lị cơng nghiệp, Hà Nội: Khoa học Kỹ thuật Hà Nội, 1999 zhenying, "zhenying.en.alibaba.com," Factory Supply Promotional Two Layers PVC Baking Oven , [Online] Available: https://zhenying.en.alibaba.com/product/60346676476805448984/Factory_Supply_Promotional_Two_Layers_PVC_Baking_Oven.h tml?spm=a2700.icbuShop.89.1.349067643lj2A8 L Dongguan jinyu Automation EquipmentCo., "detail.en.china.cn," Energysaving pvc baking oven pvc machine for pvc patch, [Online] Available: https://detail.en.china.cn/provide/p161183135.html S Đỏ, "www.sendo.vn," Mâm nhiệt bếp hồng ngoại 20cm tặng kèm cảm biến nhiệt bếp hồng ngoại - 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Research and design a SCADA system for the heating machine 1.3.2 Scope of the study Because the machine still not have basis of the experiment for running in industry... definition about heating ovens 2.1.1 Definition of heating oven An oven is a thermally insulated chamber used for the heating, baking, or drying of a substance, and most commonly used for cooking... Analyzing and summarizing experience: analyzing and summarizing to assess the demand and ability of the product Analysis to find out the limitations and love disadvantages of the device to improve and