Trang 1 MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS AUTOMATION AND CONTROL ENGINEERING
MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS AUTOMATION AND CONTROL ENGINEERING TECHNOLOGY CONTROL AND MONITORING THE AUTOMATIC WEIGHING AND PACKING RICE SYSTEM ADVISOR : TRAN VI DO, Ph.D STUDENTS : PHAN TRAN KIEU PHI HO QUANG HIEP SKL011320 Ho Chi Minh City, June 2023 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING -⸙∆⸙ - GRADUATION PROJECT CONTROL AND MONITORING THE AUTOMATIC WEIGHING AND PACKING RICE SYSTEM Student 1: PHAN TRAN KIEU PHI Student’s ID: 19151083 Student 2: HO QUANG HIEP Student’s ID: 19151055 Major: AUTOMATION AND CONTROL ENGINEERING TECHNOLOGY Advisor: TRAN VI DO, Ph.D Ho Chi Minh City, June 27th, 2023 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, , 2023 GRADUATION PROJECT ASSIGNMENT Student name: Phan Tran Kieu Phi Student ID: 19151083 Student name: Ho Quang Hiep Student ID: 19151055 Major: Automation and Control Engineering Technology Class: 1915CLA Advisor: Ph.D Tran Vi Do Phone number: 0866 408 284 Date of assignment: 06/02/2023 Date of submission: 30/06/2023 Project title: Control and monitoring the automatic weighing and packing rice system Initial materials provided by the advisor: Datasheet of Siemens Simatic HMI Model conveyor How to use loadcell, sealing part Content of the project: The system designed on SOLIDWORKS software Selection of suitable equipment for the system Realistic model construction with iron hardware using PLC control device, Loadcell weighing system and packing by heat sealing method Write a program for the system in Tia Portal V17 software Siemens Simatic HMI control interface design Graduation thesis report Final product: System model design on SOLIDWORKS The automatic weighing and packing rice system Program to control system on Tia Portal V17 software, monitoring interface on Siemens Simatic HMI Graduation thesis (word, powerpoint and experimental running video) CHAIR OF THE PROGRAM ADVISOR (Sign with full name) (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, , 2023 ADVISOR’S EVALUATION SHEET Student name: Phan Tran Kieu Phi Student ID: 19151083 Student name: Ho Quang Hiep Student ID: 19151055 Major: Automation and Control Engineering Technology Project title: Control and monitoring the automatic weighing and packing rice system Advisor: Ph.D Tran Vi Do EVALUATION Content of the project: Strengths: Weaknesses: Approval for oral defense? (Approved or denied) Overall evaluation: (Excellent, Good, Fair, Poor) Ho Chi Minh City, (month day, year) ADVISOR (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, , 2023 PRE-DEFENSE EVALUATION SHEET Student name: Phan Tran Kieu Phi Student ID: Student name: Ho Quang Hiep Student ID: 5 Major: Automation and Control Engineering Technology Project title: Control and monitoring the automatic weighing and packing rice system Name of Reviewer: EVALUATION Content and workload of the project Strengths: Weaknesses: Approval for oral defense? (Approved or denied) Reviewer questions for project valuation Mark: ……………… (in words: .) Ho Chi Minh City, (month day, year) REVIEWER (Sign with full name) Declaration Of Authorship I hereby declare that this thesis was carried out by ourself under the guidance and supervision of Ph.D Tran Vi Do; and that the work contained and the results in it are true by author and have not violated research ethics The data and figures presented in this thesis are for analysis, comments, and evaluations from various resources by my own work and have been duly acknowledged in the reference part In addition, other comments, reviews and data used by other authors, and organizations have been acknowledged, and explicitly cited I will take full responsibility for any fraud detected in my thesis Ho Chi Minh City, day month year Author (signature and full name) Author (signature and full name) Acknowledgment The graduation thesis is the last big project we have to complete in order to graduate and become an engineer This is a project that applies all the knowledge we have learned during our four years of university To have full knowledge and ability to complete the project: "Control and monitoring the automatic weighing and packing rice system", we would like to sincerely thank the school administrators of the Ho Chi Minh City University of Technology and Education for helping and creating fulfilling facilities that are helpful throughout the learning course In addition, we deeply thank the teachers in the Faculty for High Quality Training, who are kind and conscientious They help us to gain knowledge, which is fundamental and necessary to widen our mind Specially, the instructor Ph.D Tran Vi Do, who helps us to accomplish the project We sincerely thank him, thankful for his instructions and particularly research directions Moreover, my supervisor provides many valuable documents during the learning and doing the final project, these theories give a hand to iron out problems quickly And not to mention, it was the help and encouragement from family and friends that created the best conditions for us to complete However, in the process of making the project, due to my limited specialized knowledge, it is inevitable that there are some shortcomings when presenting and evaluating the problem We look forward to receiving the comments and evaluation of the teachers to make my thesis more complete Thank you sincerely! Table of Contents GRADUATION PROJECT ASSIGNMENT i ADVISOR’S EVALUATION SHEET iii PRE-DEFENSE EVALUATION SHEET iv Declaration Of Authorship v Acknowledgment vi Table of Contents vii List of Figures ix List of Tables xi List Of Acronyms xii Abstract xiii Chapter OVERVIEW 1.1 Introduction 1.2 Objectives 1.3 Research content 1.4 Limitations of the topic 1.5 The applicable ability of this project Chapter LITERATURE REVIEW 2.1 Learn about the product weighing 2.2 Learn about heat sealer 2.3 Building a model on the subject of rice weighing and packing system 2.3.1 Operated – controlled the system 2.3.2 Controlled and monitored system 2.4 The block diagram of the system Chapter HARDWARE DESIGN 3.1 Hardware requirements 3.2 Design system 3.2.1 Design software overview 3.2.2 Mechanical design 10 3.2.3 SOLIDWORKS simulated system 16 3.3 Material 17 3.4 Devices used in the project 17 3.4.1 Power 17 3.4.2 Programmable Logic Controller 1214C DC/DC/DC 18 3.4.3 Mechanical frame 20 3.4.4 Conveyors 20 3.4.5 Motor 21 3.4.6 Cylinder 24 3.4.7 Reversing valve 28 3.4.8 Relay 30 3.4.9 Button 32 3.4.10 Loadcell 32 3.4.11 Weight transmitter of loadcell 35 3.4.12 Sealing part 36 3.4.13 Electric cabinet 37 3.4.14 Electric circuit breaker (CB) 38 3.4.15 Siemens Simatic HMI 38 3.4.16 Signal light 41 3.4.17 Product sensor 41 3.5 Hardware construction 43 3.5.1 Connection diagram 43 3.5.2 Hardware assembly 45 Chapter SOFTWARE DESIGN 47 4.1 Software requirements 47 4.2 Build on software 47 4.2.1 Tia – portal v17 software 47 4.2.2 Program to active system 48 4.2.3 Control and monitoring interface on Siemens Simatic HMI 51 Chapter EXPERIMENTAL RESULTS 54 5.1 Implementation results 54 5.1.1 Achieved results on designing hardware 54 5.1.2 Achieved results on designing software 54 5.1.3 Achieved results on performances of the system 55 Chapter CONCLUSION AND RECOMMENDATIONS 60 6.1 Conclusion 60 6.1.1 System advantages 60 6.1.2 System disadvantages 60 6.2 Development direction 60 References 61 Appendices 62 CHAPTER DEVICES USED IN THE SYSTEM 4.2.2.2 Manual mode block diagram Figure 72 Manual running program The program in Manual mode is used to check the operation of the equipment If you want to check the level of activity in any device, just press the button, after the test is complete, press off Leaving this mode on helps us to test the accuracy and easily repair each device if there is an error From there, when going through Auto mode, the system will run smoothly and accurately GRADUATION THESIS 49 CHAPTER DEVICES USED IN THE SYSTEM 4.2.2.3 Auto mode block diagram Figure 73 Auto running program GRADUATION THESIS 50 CHAPTER DEVICES USED IN THE SYSTEM 4.2.3 Control and monitoring interface on Siemens Simatic HMI In this project, we use TIA Portal V17 software, and choose model corresponding to hardware PLC 1214C DC/DC/DC type 6ES7214-1AG40-0XB0 Figure 74 TIA Portal software interface Note: Name of the original save program Device configuration Main [OB1]: Where to write the main code AUTO [FC1]: Program to run Auto Block_1 [FC4]: Programming for loadcell MANUAL [FC3]: Program run Manual OUTPUT [FC2]: Program output of the system Figure 75 The subroutines used 4.2.3.1 Communication between PLC and interface Siemens Simatic HMI Figure 76 Hardware of PLC S7-1200 GRADUATION THESIS 51 CHAPTER DEVICES USED IN THE SYSTEM Figure 77 Hardware Siemens Simatic HMI Figure 78 Connection between PLC and Siemens Simatic HMI 4.2.3.2 Siemens Simatic HMI interface design The system has permissions for users Divided into groups: Users and Engineer Engineers can user administration, monitor, operate, maintenance, with username: Engineer and password: 123456 Users can only operate the system, with username: Worker and password: 1234 Figure 79 Authorization of engineers Figure 80 Authorization of Users Siemens Simatic HMI is designed with screens: main screen, auto mode screen, manual mode screen, alarm screen and trend screen GRADUATION THESIS 52 CHAPTER DEVICES USED IN THE SYSTEM a/ Main screen b/ Auto screen c/ Manual screen Figure 81 Main screen a/ Alarm screen b/ Trend screen Figure 82 Notification screen In the warning screen will display the system operation, shutdown, problem or operating mode of the system The trend screen will display waves including waves showing the amount of rice entered and waves showing the amount of rice weighed Help users easily monitor the accuracy and stability of the system GRADUATION THESIS 53 CHAPTER SYSTEM CONSTRUCTION Chapter EXPERIMENTAL RESULTS 5.1 Implementation results 5.1.1 Achieved results on designing hardware Calculation and selection of equipment suitable for the system Draw the wiring diagram of the system and block diagram of the system Draw system simulation on SOLIDWORKS software a/ Hardware design b/ Hardware construction Figure 83 Hardware results achieved 5.1.2 Achieved results on designing software Programmable control for weighing and packing rice system Can use Tia Portal software to communicate and control PLC Write a program to control the system according to the requirements of the problem Built a monitoring and control system (in two modes: manual control and automatic control) on Siemens Simatic HMI a/ Main screen b/ Auto screen c/ Manual screen Figure 84 Main screen GRADUATION THESIS 54 CHAPTER SYSTEM CONSTRUCTION a/ Alarm screen b/ Trend screen Figure 85 Notification screen 5.1.3 Achieved results on performances of the system The system is supplied with enough power and pneumatic to operate stably The motor is fast enough to pull the conveyor belt and product into the bin Load cell calibration Install the heat sealer Completed all the goals set out Figure 86 The system is completed Test to check the stability of the system: Enter any amount of rice between 200g and 400g In here, we try: 250g, 320g, 400g Finished product weight error within: 5% GRADUATION THESIS 55 CHAPTER SYSTEM CONSTRUCTION The mouth of the bag is sealed, opening in the range of about to cm is considered to reach: a/ Finished product b/ The mouth is reversed Figure 87 Bag of rice after weighing and sealing Test 250g (Error: 5%, range: 237.5g - 262.5g) Times 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Operation Weighing system value (g) Actual weight value (g) Error (%) Right 253 257.52 254.81 253 257.7 255.71 255.35 257.7 254.45 251.56 255.6 253 256 255.23 253.55 254.27 254.27 253 253 257 253 254.701 255.46 253 254.27 252 255 252 248 248 252 253 255 259 250 254 253 255 258 252 256 257 258 257 260 258 257 253 251 252 0.8 0.8 0.8 0.8 0.8 1.2 3.6 1.6 1.2 3.2 0.8 2.4 2.8 3.2 2.8 3.2 2.8 1.2 0.4 0.8 x x x x x x x x x x x x x x x x x x x x x x x x x GRADUATION THESIS Wrong Sealed Achieved Not achieved x x x x x x x x x x x x x x x x x x x x x x x x x 56 CHAPTER SYSTEM CONSTRUCTION Operation Times Weighing system value (g) Actual weight value (g) Error (%) Average 354.646 254.2 1.68 Percentage (%) of correct operation (tried 25 times) 25 25 98.32 Sealed Right Wrong Achieved Not achieved 100 84 16 Test 320g (Error: 5%, range: 304g - 336g) Times 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Average Operation Weighing system value (g) Actual weight value (g) Error (%) Right 326.43 320 82 326.97 326.7 326.43 321 326.97 323.17 326.61 323.71 326.7 327.32 326.94 320.82 326.97 325.52 326.97 327.52 328.23 326.79 320.82 325.16 326.7 320.18 325.52 316 315 316 317 317 316 315 319 313 321 318 319 316 315 321 317 320 322 316 321 309 318 317 316 317 1.25 1.5625 1.25 0.9375 0.9375 1.25 1.5625 0.3125 2.1875 0.3125 0.625 0.3125 1.25 1.5625 0.3125 0.9375 0.625 1.25 0.3125 3.4375 0.625 0.9375 1.25 0.9375 x x x x x x x x x x x x x x x x x x x x x x x x x 325.2388 317.08 0.9125 GRADUATION THESIS Wrong Sealed Achieved Not achieved x x x x x x x x x x x x x x x x x x x x x x x x x 57 CHAPTER SYSTEM CONSTRUCTION Operation Sealed Times Weighing system value (g) Actual weight value (g) Error (%) Right Wrong Achieved Not achieved Percentage (%) of correct operation (tried 25 times) 25 25 99.0875 100 88 12 Test 400g (Error: 5%, range: 380g - 420g) Times 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Weight Average Percentage (%) of correct operation (tried 25 times) Operation Weighing system value (g) Actual weight value (g) Error (%) 401.11 407.26 401.27 406.54 404.34 406 404.3 404 406.21 405.27 401.34 404.37 406.67 406.21 405.89 400.27 408.33 404.32 401.23 409.6 405.34 405.57 407.26 403.11 404.91 379 385 386 390 381 386 387 384 382 386 379 383 386 385 382 380 390 383 382 392 386 384 383 381 388 5.25 3.75 3.5 2.5 4.75 3.5 3.25 4.5 3.5 5.25 4.25 3.5 3.75 4.5 2.5 4.25 4.5 3.5 4.25 4.75 404.8316 384.4 3.9 25 25 96.1 GRADUATION THESIS Right Wrong Sealed Achieved x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x 92 Not achieved x x x x x x x x x x x x x x 72 28 58 CHAPTER SYSTEM CONSTRUCTION After many tests, the following results were obtained: Table Statistics of many test runs Required volume of rice (g) 250 320 400 Actual weight value (g) 254.2 317.08 384.4 Error (%) 1.68 0.9125 3.9 From the above table, we have: The weighing system satisfies the error rate of the system: ~5% Welding system accuracy: ~81% Accuracy of the whole system: ~89.6% The system operates stably, accurately and satisfies the set requirements GRADUATION THESIS 59 CHAPTER EXPERIMENTAL RESULTS Chapter CONCLUSION AND RECOMMENDATIONS 6.1 Conclusion 6.1.1 System advantages The system runs the scale and welds the mouth of the rice bag according to the set requirements The system has set the set requirements System accuracy: ~89.6% Easy to study and expand further 6.1.2 System disadvantages There is no supply system, so the leveling must be done by hand, leading to if the mounting is not beautiful, it will not be straight, it will make the mouth of the bag open when welding and the weld is not beautiful Since there is no PID system, the temperature at the heat seal is not equal at all points, which causes the mouth of the bag to appear non-stick at some point 6.2 Development direction Upgrading the sealing device: use sensor PT100 to read the analog signal to adjust the sealing temperature more appropriately and proactively, develop more PID controller to balance the temperature at every point on the solder bar Therefore, the ability to seal the mouth of the bag ensures higher accuracy Use more load cells to increase weighing accuracy Larger product upgrades are more relevant in practice GRADUATION THESIS 60 REFERENCES References [1] Tổng cục thống kê Việt Nam, Infographic tình hình kinh tế - xã hội tháng 01 năm 2023 https://www.gso.gov.vn/du-lieu-va-so-lieu-thong-ke/2023/01/infographic-tinh-hinhkinh-te-xa-hoi-thang-01-nam-2023/ [2] Snehashis Das, Avijit Karmakar, Pikan Das, Biman Koley (2019), Manufacture of Electronic Weighing Machine Using Load Cell, IOSR Journal of Electrical and Electronics Engineering [3] H Howard (1972), Heat Sealing System for Plastic Containers [4] Carlos R D S Copia (1982), Cutting/sealing device for plastic bag making machines 61 Appendices Appendices Programmable PLC controller S71200 https://drive.google.com/file/d/1GrWhl_nWMITsXBj7xO0OVujX47QOQL9v/view?usp =sharing GRADUATION THESIS 62 S K L 0