(Đồ án hcmute) controlling and monitoring fabric dyeing machine

BỘ GIÁO DỤC VÀ ĐÀO TẠO TRƯỜNG ĐẠI HỌC SƯ PHẠM KỸ THUẬT TP.HCM KHOA ĐIỆN - ĐIỆN TỬ ĐỒ ÁN TỐT NGHIỆP KHOA ÐÀO TẠO CHẤT LUỢNG CAO CONTROLLING AND MONITORING FABRIC DYEING MACHINE GVHD: ThS TRƯƠNG ĐÌNH NHƠN SVTH : TẠ QUANG MINH 12151051 TRƯƠNG LÊ ANH DŨNG 12151012 S KL 0 6 Tp Hồ Chí Minh, tháng 07/2016 an HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION HIGH QUALITY FALCUTY GRADUATION THESIS CONTROLLING AND MONITORING FABRIC DYEING MACHINE Instructor: MR TRUONG DINH NHON, PhD Student : TA QUANG MINH 12151051 TRUONG LE ANH DUNG 12151012 Course : 2012-2016 Study Branch : AUTOMATION Ho Chi Minh City, July 2016 an HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION HIGH QUALITY FALCUTY GRADUATION THESIS CONTROLLING AND MONITORING FABRIC DYEING MACHINE Instructor: MR TRUONG DINH NHON, PhD Student : TA QUANG MINH 12151051 TRUONG LE ANH DUNG 12151012 Course : 2012-2016 Study Branch : AUTOMATION Ho Chi Minh City, July 2016 an SOCIALIST REPUBLIC OF VIETNAM Independence- Freedom- Happiness *** -Ho Chi Minh City, July 15th, 2016 GRADUATION THESIS’S MISSION Full Name: Studying Branch: Instructor: Received Day: ID Number: Class: Phone Number: Submitted Day: Thesis’s Name: Initial Data: Content: Product: DEAN INSTRUCTOR an SOCIALIST REPUBLIC OF VIETNAM Independence- Freedom- Happiness *** -Ho Chi Minh City, July 15th, 2016 INSTRUCTOR’S NOTE Student’s Name: .ID Number: Studying Branch: Thesis’ Name: Instructor’s Name: COMMENTS: About Content of Thesis: Strength: Weakness: Allow or Disallow to process further dissertation? Rate: Mark :……………….(By word: ) Ho Chi Minh City, July 15th, 2016 Instructor (Sign and write full name) an SOCIALIST REPUBLIC OF VIETNAM Independence- Freedom- Happiness ******* REVIEWER’S NOTE Student’s Name: .ID Number: ID Number: ID Number: Studying Branch: Thesis’s Name: Reviewer’s Name: COMMENT: About Content of Thesis: Strength: Weakness: Allow or Disallow to process further dissertation? Rate: Mark:……………….(By word: ) Ho Chi Minh City, July 15th, 2016 Reviewer (Sign and write full Name) an an Acknowledgements First, we are very pleased to say our sincerities “Thank you” to all the teachers who are working at Ho Chi Minh City University of Technology and Education, especially to the teachers of High Quality Falcuty who have given us valuable knowledges so that we could finish this thesis And we sincerely thank our instructor: Mr Truong Dinh Nhon, PhD; who has helped, supported and guided us with all his heart during our process We also sincerely thank you to Mr Nguyen Minh Tam, PhD; Mr Ngo Van Thuyen, PhD; Mr Hoang Ngoc Van, MS ; Mr Ta Van Phuong, MS; and all the teachers who are working at Rockwell Automation Lab for helping and giving us opportunities to research and practice at Rockwell Automation Lab And a sincere Thank to our relatives and friends who have helped and supported us throughout Graduation Thesis ProJect Team i an Introduction Modern industry is growing and dominant strongly thesedays Although automatic industry is a new industry, it is necessary in any manufacturing systems Automatic system is gradually replacing manual systems, as well as human in operating any works, even the most sotisphicated works It helps increase productivity as well as product’s quality and reduce producing cost Systems must be equipped with controlling devices such as PLC controllers, which are used to control, monitor and collect system’s data These systems are able to control in real-time mode through network systems Beside that, systems also have many databases, abilities of identifying and fixing damaged parts, creating statistics, reports Therefore, the study of PLCs and automatic systems in the industry is essential Infact, theory must be associated with practice Working with real model is a chance for every students to practice what he/she has learnt It is an opportunity to apply learned knowledges in practical circumstances so that we can learn and research more about both theory and practice, create our own products by what we have learnt Throughout this thesis, we also have learnt more about programming and supervising system on SCADA interface, HMI screen, etc During working on this thesis, we have faced many problems with designing, building model Because of limited experience, knowledge, time and funds, there will be some mistakes or problems that occur when operating the model We are very pleased to receive any feedbacks, comments about our thesis in order for us to complete and improve it in future Sincerely, Project Team ii an Tóm Tắt Đề Tài Đề tài xây dựng dựa mơ hình máy nhuộm vải thực tế Nhóm thiết kế mơ hình có khả pha màu hoàn toàn tự động, sử dụng cảm biến nhiệt PT100 kiểm soát nhiệt độ gia nhiệt bồn nhuộm Biến điều khiển tốc độ động quay trống nhuộm nhằm tăng hiệu suất cho trình nhuộm vắt vải Để điều khiển giám sát q trình hoạt động máy nhuộm vải nhóm sử dụng: PLC CompactLogix L32E, biến tần PowerFlex 700S hãng Allen-Bradley, phần mền giám sát FactoryTalk View, Panelview Builder 32 RockWell Automation số phần mềm khác sử dụng hệ thống Toàn trình điều khiển giám sát hai giao diện SCADA HMI Giao diện SCADA ứng dụng nhiều nhà máy tự động điều khiển đại với tính ưu việt khả giám sát, lập biểu đồ giúp người vận hành quan sát định kịp thời; giao diện thân thiện, dễ sử dụng, khả bảo mật cao Bên cạnh đó, phần mềm FactoryTalk View cịn hỗ trợ việc mở rộng khả liên kết PLC hãng khác hãng thông qua OPC, ứng dụng phần mềm Kepware để lấy biến trung gian Giao diện HMI cho phép người dùng thao tác hình cảm ứng HMI PanelView 600 Tất hoạt động, cố, trạng thái hệ thống giám sát trên hình HMI máy tính iii an Figure 37Mixing and stiring color screen on HMI Figure 38 Soaking process screen on HMI 93 an Figure 39 Dyeing fabric process screen on HMI Figure 40 Squeezing fabric screen on HMI b, Manual mode Figure 5.43 is the parameter setting screen for creating new fabric process Operator can adjust Solenoid valves properly to create new colors for soaking and dyeing process Shown as in Figure 5.44 94 an Figure 41 New fabric parameter setting screen on HMI Figure 42 Color mixing and stiring screen in Manual mode on HMI Controlling soaking, dyeing and squeezing screen in Manual mode on HMI is shown as in Figure 5.45 95 an Figure 43 Soaking, dyeing and squeezing screen in Manual mode on HMI c, Alarm screen Figure 5.46 is warning screen which warns operator to know about system errors to fix as soon as possible to ensure people and devices’ safety Figure 44 Warning screen 96 an 5.4 Comment From practical results and operating process, designed system satisfies processing requests: - Controlling interface on SCADA and HMI screen: friendly, convenient for controlling, monitoring and warning - Installed Solenoid valves are not leaked - Dyeing motor operation is stable - Heating devices operation is stable and safe - Sensor measures temperature exactly 97 an Chapter 6: CONCLUSION AND DEVELOPMENT SUGGESTIONS Conclusion and development At the beginning of this chapter, there will be comments- evaluation of achieved results from chapter 5, emphasizing strengths as well as weaknesses of the model/system At the end, there are solutions for solving weaknesses as well as developing plans to upgrade model and controlling interface to optimize system in future 6.1 Conclusion From results of hardware and software operations which are performed detailly in Chapter Compare those results to designing requests, we see that system has operated well enough to satisfy requirements & targets with these features in designing and technique: - Dyeing system with compact structure, convenient for stimulating purposes that supports further studies and researches - Model operates well, stabily in allowed range, meets controlling requirements which have been mentioned since the beginning of this thesis - SCADA interface is integrated fully with controlling- supervising functions, visual interfaces, clear images, icons suit devices, helps operator control and supervise entire operation of system easily - Intergrating login interface due to operator’s level, which allows us to manage controlling operations with proper operating function, help increase safety in system controlling process - Errors warning function occurs on supervising interface to make it more convenient to realize and trobleshoot At the same time, to support reporting, we have succeeded in bringing daily qualified and failed fabrics that are created during manufacturing processes as well as login time of engineers and workers in form of Excel files in order to manage and check regularly 98 an Along with said strengths, this system still has some weaknesses due to limited time and fund Besides that, there are some other weaknesses that can be listed: - Model doesn’t have flow sensor Water amount is only measured by time and water’s speed This decreases system’s precision - System doesn’t use Encoder Therefore, motor’s reaction speed from inverter to PLC has a little deviation - Heating device doesn’t work well enough It cannot proceed heating for squeezing process due to heating device’s ( water heating resistor) safety 6.2 Development From our obtained experiences, we suggest some solutions for developing this model: - Use steam that has been heated outside to supply for dyeing tub instead of using water heating resistor, this will keep temperature increase satbily dyeing fabrics’ quality, safety for operators, devices - Change electric valves by mini pumber to raise dyeing operation’s productivity - Design automatic input/output part that put fabrics in and out in dyeing process 99 an Documentations  English Documents Compact 32-point Solid-state 24Vdc Source Output Module Installation Instructions (Copyright Rockwell AUTO Technologies 2003) Compact 1769-IF4 Analog Input Module (Copyright Rockwell AUTO Technologies 2003) Factory Talk Alarms and Events System Configuration Guide (Copyright Rockwell AUTO Technologies 2009) Factory Talk Security System Configuration Guide (Copyright Rockwell AUTO Technologies 2009) Factory Talk View Site Edition User’s Guide (Copyright Rockwell AUTO Technologies 2009) Logix5000 Controllers Common Procedures Programming Manual (Copyright Rockwell AUTO Technologies 2007) PanelView 600 Terminals - Installation Instructions (Publication 2711IN010F-MU-P - August 2007) PanelBuilder Software User Manual (Copyright Rockwell AUTO Technologies) PanelView Standard Operator Terminals User Manual (Copyright Rockwell AUTO Technologies)  VietNamese Documents  http://midatex.com.vn/tin-cong-ty/quy-trinh-cong-nghe-det nhuom hoan-tat- vai-det-kim-cong-ty-det-nhuom-minh-dat-midatex-/163/  https://www.facebook.com/permalink.php?id=369601466466500&story_fbid =438635329563113  http://luanvan.co/luan-van/do-an-thiet-ke-qui-trinh-cong-nghe-tien-xu-lynhuom-va-hoan-tat-vai-det-kim-tu-soi-peco-6733-voi-cong-suat-2000tannam-33115/ 100 an ADDENDUM Inverter setting parameters - Set motor’s parameters ( from Par to Par 7) - Set Par10’s speed with any value except - Set Min and Max speed for motor by importing proper value into Par30(Min ) and Par31 (Max), a minus which is put before speed’s value is the speed’s values in opposite direction - Set bit for Par 153 (Control Option) with value of so that motor only rotates forward or with value of so that motor rotates forward- backward - In order for motor to speed up or down by purpose, we set Par32 ( Speed up time) and Par33( Speed down time) - Choose proper stop-mode for motor by Par168 There are stop-modes in Par168: Stop according to speed down time, Stop immediately by current’s limit, Stop and set current to (In this project we choose “Stop according to speed down time” ) - Choose 2- Sensorless mode in Par 222 in order not to be feedbacked by Encoder - Choose 1- V/Hz Mode in Par485 to control motor by voltage is recommended to apply for pumbing motor DeviceNetSetting steps for Inverter controlling through DeviceNet network Module 20-COMM-D Adapter is the module that connects inverter to scanner in DeviceNet network Some issues should be noticed when connecting inverter into communication: - Switches can be turned to adjust addresses for Note, in order to differ from other Notes in network - On module, we can set data rate for transmitting data in network We should put switches at PGM location so as to be convinient for setting parameters afterwards 101 an - Connect DeviceNet ‘s cables properly with exact signs on each wires Setting parameters for Adapter and Inverter: In order for inverter to transmit in DeviceNet network, we need to configurate some necessary parameters for Adapter and Inverter: - Par 03: [ DN addr Config]: Re-set Note’s address - Par 05: [ DN Rate Config]: configurate data rate - Par 09: [ Reset Module]: reset module This is a must so that module 20COMMD can perform transmitting and receiving data after being configurated - Par 13: [ I/O Config]: Allow or disallow transmitting and receiving data - Par 25: [ M-S Input]: Allow or disallow data in Master – Slave Mode - Par 26: [ M-S Output]: Allow or disallow to send data in Master- Slave Mode - Setting parameters for Inverter: Basic setting steps are just like part b, which is already shown One difference is : in Par 27, we need to choose 16- DPI Port This is performed to connect between DeviceNet and Inverter - To control inverter through DeviceNet, we have to know memorial area of Inverter 102 an Following chart describes memorial cells’ arrangement and specific functions of each cells Output means data which is exported from PLC Input means data which is read from Inverter 103 an Every Bit’s Function in Logic Command Word is described in following chart: 104 an Every Bit’s Function in Logic Status Word is described in following chart: 105 an 106 an S an K L 0 ... labor cost and increase productivity an Figure A fabric dyeing machine model 1.2 Project’s targets ? ?CONTROLLING AND MONITORING FABRIC DYEING MACHINE? ?? is researched from a real fabric dyeing system... quality after dyeing Used water must be colorless, smelless and has proper hardness - Fabric material handling: fabric quality checking and fabric classifying must be done before chemical handling... dyestuffs into the fabric fibers Pigment dyeing is to overlay unsoluble dyestuffs onto to fabric surface, block dyeing and gel dyeing helps dyestuffs work well in the dyeing process Dyeing process