OVERVIEW
Introduction
Metal plating is a surface finishing technique that applies a thin layer of metals like chromium, nickel, or copper onto objects to enhance their appearance and provide benefits such as corrosion resistance, improved hardness, wear resistance, and reduced friction This process is prevalent across multiple industries due to its aesthetic appeal and durability Common applications of metal plating can be found in both industrial settings and everyday products.
- Automotive Industry: Metal plating is widely used in the automotive industry for decorative purposes on bumpers, grilles, door handles, and various trim components It provides a shiny, corrosion-resistant finish
In the aerospace industry, metal plating is essential for enhancing the durability and performance of critical components It provides corrosion resistance, wear resistance, and a low coefficient of friction, making it ideal for aircraft engine parts, landing gear components, and hydraulic cylinders.
- Electrical Industry: Metal plating is applied to electrical connectors and contacts to enhance conductivity, corrosion resistance, and durability
- Household Appliances: Metal plating is used on various household items, such as faucets, showerheads, door handles, and kitchen utensils, to provide an attractive and durable finish
- Industrial Equipment: Metal plating is employed in the manufacturing of industrial equipment, such as pumps, valves, cylinders, and hydraulic components, to improve wear resistance and corrosion protection
- Medical Equipment: Metal plating is utilized in medical equipment manufacturing for items like surgical instruments, medical devices, and dental tools due to its biocompatibility and corrosion resistance
General outline of the chromium plating technology 3 process:
Surface Cleaning of Metal Plating
- Global Metal Plating Market Size is expected to grow from USD 2.02 billion in
The global metal plating market is projected to grow from USD 3.06 billion in 2017 to USD 3.06 billion by 2030, exhibiting a CAGR of 5.1% This growth is driven by the rising demand for decorative and protective coatings across various sectors, including automotive, appliances, gaming, heavy trucks, motorcycles, and plumbing Additionally, the increasing need for lightweight and corrosion-resistant materials is further propelling the expansion of the metal plating industry.
In the Vietnam Metal Plating Market, data derived exclusively from members of the Vietnam Steel Association (VSA) indicates that internal consumption reached 1.65 million metric tons during the first 11 months of 2014 This figure does not account for additional companies that are not part of the VSA.
2014, the sales volume of all members in VSA may reach 1.8 million MT, while the total consumption of the entire country may reach 2.6 million MT this year
Figure 1.1: Market share of coated steel sheet of 2014
In today's competitive market, a product must feature an efficient plating system that guarantees both high production and quality output C.Q.S PRECISION DIE CASTING INC, located in Ho Nai Industrial Zone, faces challenges with its metal plating system, including the lack of a communication network for the PLC and reliance on a single PLC for process control without remote monitoring Furthermore, extensive electrical wiring complicates repairs and troubleshooting, leading to significant time and resource losses Additionally, employees are required to work in close proximity to hazardous chemicals, contributing to decreased productivity and financial losses for the company.
Figure 1.2: Electrical cabinet with only a single PLC
Figure 1.3: Metal plating system at C.Q.S PRECISION DIE CASTING INC
The metal plating system is a valuable investment due to its significant applications and high output However, one critical aspect that often goes overlooked is surface cleaning In electroplating technology, maintaining a clean surface prior to the plating process is essential for achieving optimal results.
The metal cleaning process prior to plating is crucial for ensuring product quality and enhancing the adhesion of the plated layer Contaminants such as grease, corrosion, dirt, and foreign materials can negatively impact the adherence and durability of plated deposits The quality of an electrodeposit is directly linked to the surface it is applied to, making it essential to achieve high-quality protective, decorative, or functional metal deposits through proper pretreatment of the base metal surface.
Consequently, investing in a pre-plating cleaning process is necessary to ensure product quality and increase production efficiency
Overview of Surface Preparation Methods
Metal cleaning is usually accomplished by six general methods of handling the work in relation to the cleaning media, namely:
The three primary methods for cleaning surfaces are steam gun, solvent vapor degreaser, and abrasion techniques Mechanical methods such as grit blasting, shot blasting, or tumbling will not be discussed in this context, as they fall outside the scope of plating line processes.
The project will apply two methods:
Industrial plating systems are typically large and operate in hazardous environments where they are frequently exposed to various chemicals Such toxic conditions can have detrimental effects on human health, highlighting the importance of safety measures in these workplaces.
Topic Goal
The objective of the project is to design, construct, control and monitor the system of metal cleaning process before plating.and the final stage of the drying process, which
CHAPTER 1: OVERVIEW can address the remaining issues (long electrical wiring, failure to ensure occupational health and safety) of the existing system at C.Q.S PRECISION DIE CASTING INC by using industrial communication
- With a single load, the crane can lift 5kg of products
- Communication feature between PLC modules
- The system can wash off grease, dirt, oxidized rust, etc and dry
- The chemical tank for product cleaning is controlled by PID temperature in accordance with the production process.
Topic Limit
The topic only 3 steps: Degreasing -> Rinsing water -> Drying
This article focuses on selecting PID parameters to achieve essential quality criteria in the time domain, such as overshoot and transient time However, the discussion of minimizing integration criteria and exploring other control techniques is outside the scope of this topic.
By observing real industrial systems, the team improved the temperature control part for the chemical tank Chemicals that are in the right temperature range will provide better cleaning results.
Project Contents
The rest of the thesis has the following content:
Chapter 2 Theoretical Basis: Presenting the requirements of the aluminum casting product cleaning system and the problems related to the technology of the system
Chapter 3 Hardware Design: Based on the theory and requirements of the system in Chapter 2, this chapter will select and design hardware
Chapter 4 Software Design: This chapter will present the software and control design flowcharts for the model
Chapter 5 Result: Presents the results obtained on hardware, software and solved problems
Chapter 6 Conclusion and Development: Systematic review, model development and refinement.
THEORETICAL BASIS
Chapter Introduction
Presenting requirements of the system to be designed, issues related to the technology of the system.
Technological Process
Workers will place aluminum blocks (specifically, car wheels) into metal baskets Once completed, the worker will notify the operating room to run the system
The basket feeding system contains aluminum blocks that are moved through and immersed in the degreasing chemical tank
The system continues to pass the basket containing the aluminum blocks through and immerse in the degreasing chemical tank
The system continues to put the basket containing the aluminum blocks moving through and dipping into the water tank
The system further proceeds to transport the basket containing aluminum blocks, facilitating their movement and subsequent immersion into the water tank
The system systematically conveys the basket containing aluminum blocks, facilitating their movement and subsequent immersion into the oxidized rust- removing chemical tank
Continuing its operation, the system persistently transports the basket containing aluminum blocks, facilitating their movement and subsequent immersion into the water tank
In a continuous manner, the system proceeds to convey the basket containing aluminum blocks, facilitating their movement and subsequent immersion into the water tank
The system continues to pass the basket containing the aluminum blocks through and immerse in the surface treatment chemical tank
The system continues to put the basket containing the aluminum blocks moving through and dipping into the water tank
The system continues to put the basket containing the aluminum blocks moving through and dipping into the water tank
The final stage of the system involves the drying process
Upon completion, the system will place the finished products onto pallets for transportation to the next stage of the process.
Cleaning Methods
There are many cleaning methods used in industry to remove dirt, grease, and other impurities from the surface of products Here are some common cleaning methods:
- Soak cleaning: Soak in cleaning chemicals to disperse and remove surface dirt Common cleaning chemicals include acids, alkalis, organic solvents, or mixtures of them
Electrocleaning is an effective cleaning process that utilizes electric current in an electrolytic solution to remove contaminants from metal components During this procedure, the workpiece is submerged in an electrolyte solution, which is usually either alkaline or acidic, ensuring thorough cleaning and preparation for further processing.
CHAPTER 2 THEORETICAL BASIS solution The part is connected to the positive terminal (anode) of a power source, while a conductive electrode or a cathode is connected to the negative terminal
Spray cleaning utilizes high-pressure jets of liquid to effectively eliminate contaminants from surfaces This process involves applying a cleaning solution or solvent through specialized spray nozzles, which dislodge and remove dirt, grease, and other particles.
All cleaning methods have their own advantages and disadvantages Often a combination of cleaning methods is used to achieve the best results and meet the specifications of each application
Here are some pros and cons of common cleaning methods:
- Effective in removing stubborn and strong impurities
- Lower equipment and energy costs
- Strong chemicals that can be harmful to the environment and health
- Requires chemical waste treatment process
- Effective in removing rust - Need to use high energy and provide electrical system stability
- Not suitable for some plating systems
- Electrocleaning processes can be more complex
- Effective in removing stubborn dirt
- Suitability for large-scale cleaning operations and various cleaning solutions or solvents
- Spray cleaning processes can be more complex
- Higher equipment and energy costs
Selection of the appropriate cleaning method depends on the type of contaminant, the type of material and the specific requirements of the manufacturing process The use
CHAPTER 2 THEORETICAL BASIS of modern technology and equipment, together with quality and safety management, is important to ensure efficiency and good results in the cleaning process.
Test Methods for Cleaniness
After completing the surface cleaning step, you should check the cleanliness level in the materials before starting the plating process for the best effect
The product is thoroughly cleaned prior to plating when it has been completely removed from the surface of oil, dirt, soil, plaque, rust, contaminants, and other webs
The eye serves as an effective analytical instrument for identifying issues in the cleaning process A careful visual inspection of the parts can quickly reveal any inadequacies in cleaning, as changes in the surface appearance or the quality of the plated deposit often signal insufficient cleaning.
The Water Break test assesses the cleanliness of a surface using fresh, uncontaminated water A clean surface should display a continuous and uniform water film, indicating the absence of hydrophobic contaminants like grease When free of such impurities, water droplets will spread evenly, forming a thin and consistent film.
The White Glove test involves wiping the surface of a component with a white glove, cotton swab, or towel tissue to check for cleanliness After the surface is wiped, the material used for cleaning is inspected for any black, gray, or off-white residues or oil stains, indicating potential contamination.
The Pumice Scrub test involves removing the part for cleaning and scrubbing it with a soft, wet bristle brush dipped in pumice After thoroughly rinsing with water, the cleaned part is placed back on the rack and plated If the part appears brighter than the others post-plating, it indicates that the cleaning process was insufficient.
HARDWARE DESIGN
Chapter Introduction
In this chapter, our team surveys actual devices to create comprehensive block diagrams for the entire system, detailing the function of each block We then delve into the design of each block, selecting appropriate devices to fulfill the required functions Finally, we construct a diagram that illustrates the connections between the PLC and the devices, specifying the addresses for each connection, along with a diagram of the system's dynamic circuits.
Chapter Contents
The hardware design requirements are as follows:
- Capacity of the system: 5kg product/load
- Temperature control for degreasing chemical tank
Based on the design requirements mentioned above and the methods in section 2.3, the group proposes the system of Surface Cleaning and Drying Process for Metal Plating System:
- Move the crane horizontally left/right, control the AC motor speed accordingly, the purpose is to keep the product stable
- Move the crane vertically up/down direction using an AC motor with a gearbox and using a limit switch or sensor to stop the motor
- Chemical tank with temperature PID control for degreasing chemical tank The temperature of the chemical tank is always in the range of 55-60 o C to ensure compliance with the manufacturer's recommendations
- The drying process uses a thermistor or a lamp and fan to blow hot air to dry the object
- The electrical cabinet has 3 indicator lights (Red: the system is being powered; Yellow: the system has a problem, error; Green: the system is operating normally),
1 emergency stop button and 1 HMI screen
The cleaning process is remotely managed through an Ethernet network linked to a network switch, which connects to the main electrical cabinet at the end of the process to ensure occupational health and safety protection.
- All systems are controlled through HMI screens mounted on electrical cabinets and SCADA systems are located in the operating room
From design requirements, the technical process diagram is in Figure 3.1:
Workers will place metal blocks in metal baskets
Once completed, the worker will notify the operating room to run the system
The basket system contains metal blocks that are moved through and immersed in a chemical tank
The system continues to put the basket containing metal blocks moving through and dipping into a water tank
- Dipping time: Twice in a role
The final stage of the system involves the drying process
The system continues to transport the product through the hanging drying process, the fan will blow hot air flow through the product to dry
After completion, the system will place the product on the pallet to be transported to the next stage.
Block Design
Slave Controller Block Switch Ethernet
The sensor block is equipped with heat sensors that monitor the temperature of chemical tanks and optical sensors on cranes that transmit data to the central processing block The temperature sensors provide output signals ranging from 4-20mA or 0-10V, while the optical sensors deliver output signals of 0/24V voltage.
The Central Control Block, utilizing a Master-Slave configuration, comprises two PLCs interconnected through an Ethernet port This setup is crucial for processing signals from both digital and analog sensor blocks, generating control signals that adjust temperature within a range of 0-10V, and managing the operation of motor and drying blocks effectively.
Chemical tank temperature block: PID controlled temperature output signal (0- 10V) to SSR to control heating rod input voltage This PID controller is already integrated in the control block
A crane block features a three-phase motor regulated by an inverter and a single-phase motor managed by a dynamic circuit The system's central processing unit transmits signals following the RS-485 communication standard to the inverter, ensuring efficient operation and control.
Drying block: Consists of two cooling fans and two incandescent lamps to create drying temperature and is controlled through the dynamic circuit and the central processing block
Monitoring block: Including HMI screen mounted on the electrical cabinet and control through smartphone
Communication block: Including module CM1241 RS422/485 to connect with PLC and module TP-Link TL-SF1005D for all device to connect.
Select Device
The Siemens S7-1200, introduced in 2009 as a successor to the S7-200, is a programmable logic controller (PLC) known for its compact design and cost-effectiveness This advanced device boasts a powerful instruction set that enables optimal application solutions Notably, the S7-1200 features a PROFINET port, supporting both Ethernet and TCP/IP standards, making it a versatile choice for modern automation needs.
Figure 3.3: Module S7 1200 CPU 1214C DC/DC/DC PLC Siemens Simtics S7-1200 CPU 1214C DC/DC/DC specifications:
- SIMATIC S7-1200 CPU 1214C DC/DC/DC (6ES7214-1AG40-0XB0)
- Onboard I/O: 14 DI 24VDC; 10 DO 24V DC; 2 AI 0-10VDC
Only one module PLC S7 1200 1214C DC/DC/DC connects with the other devices, and Figure 3.4 shown the wiring diagram of Master PLC
Figure 3.4: Master PLC wiring diagram
Including Module CPU 1214C DC/DC/DC connect with module CM1214 and module SM1232
Figure 3.5: Analog Output Module SM 1232 Analog Output Module SM 1232 specfications:
- SIMATIC S7-1200 SM 1232 (6ES7232-4HB32-0XB0)
- Onboard I/O: 2 AO +/-10V, 14-bit resolution or 0-20mA/4-20mA, 13-bit resolution
Industrial production systems are structured across multiple management levels, each responsible for measuring, collecting, and controlling specific system components Consequently, SCADA systems are similarly organized into distinct levels, with each level tasked with performing essential functions tailored to its specific role within the overall system.
- Collecting data remotely (via data transmission) of production and organizational data the storage of data (about production history, about operation events, about alarms, )
- Control and monitor the production system based on collected data
- Perform data communication in and out of the system (read/write data) PLC/RTU, reply to request messages from superior about data, about system operation)
Figure 3.7: HMI Weintek MT8071iE HMI Weintek MT8071iE specifications
- Display: 7” TFT LCD Touch Panel
- I/O Port: USB 2.0 x 1, Ethernet, COM1: RS-232, COM2: RS-485 2w/4w
To effectively indicate the system's operating status and alarm alerts, the team has selected DC24V round lights in red, yellow, and green as alarm devices for the model The chosen device is the AD16-16C signal indicator light, which is installed on the front of the electrical cabinet Detailed technical specifications for the AD16-16C light can be found in the appendix section.
Figure 3.8: AD16-16C signal indicator light
There are two commonly used communication standards of Siemens: Ethernet (RJ45) and Modbus (RS485) Among them, Ethernet is used the most
Communication between PLCs, HMIs, SCADAs by Ethernet communication standard is a popular choice and easy to install for users
In order for devices to be able to connect to each other, we need a common connection device called an Ethernet switch
Because the project which does not require high security as well as industry standards, the TP-Link TL-SF1005D Module is a perfect choice for this task
Figure 3.9: Module TP-Link TL-SF1005D Table 3.1: Advantage and Disadvantage of communication module
- Remote access and diagnostics Support various communication protocols
- Allowing multiple devices to be connected to a single communication line
Figure 3.10: Communication module CM 1241 Communication module CM 1241 specifications:
- SIMATIC S7-1200 CM 1241 (6ES7241-1CH32-0XB0)
- Onboard I/O: RS422/485, 9-pole D-sub (socket)
To effectively control the crane used for transporting goods during cleaning, a proximity sensor was employed to accurately detect the location of the sinks Several types of proximity sensors are available that can meet the specific requirements of the project.
Table 3.2: Advantage and Disadvantage of some proximity sensors
- Ability to detect non- conductive materials
- No direct contact with the object is required for detection
- High accuracy and ability to detect small objects
- Affected by ambient environment and humidity
- The ability to detect conductive materials, such as metals
- Stable operation in noisy industrial environment
- Direct contact with the object is required for detection
- Influenced by magnetism from other sources in the environment
- Ability to detect objects in long range
- Fast response speed and high accuracy
- Easily affected by ambient light
- Difficult to survey objects in dusty and dirty environments
Electromagnetic sensors face significant limitations when in direct contact with obstacles, while capacitive sensors are adversely impacted by humidity, making them unsuitable for moist environments In contrast, optical sensors offer superior advantages, making them more appropriate for applications in challenging environmental conditions.
Figure 3.11: Optical sensor Optical sensors specifications:
A temperature sensor is a device that transforms temperature measurements into electrical signals, such as resistance, current, or voltage These signals are subsequently processed by a Programmable Logic Controller (PLC) for analysis and control purposes.
Based on the analysis in Chapter 2, the degreasing chemical needs to operate at a temperature of 60°C Therefore, temperature sensors commonly used in the industry include thermocouples and RTD
While thermocouples and Resistance Temperature Detectors (RTDs) may look alike externally, they have distinct construction and operating principles A detailed comparison of their differences can be found in Table 3.3.
Table 3.3: Comparison between thermocouple and RTD
- Capable of measuring high temperatures
- Higher accuracy than thermocouples, easier to use, no limitation on the length of the cable
- Ease of error by environmental factors, not highly sensitive
- Limited measurement range but higher cost compared to thermocouples
- In the industries of industrial production, metallurgy, education, or material processing
- In general industries, environmental industry or material processing, chemicals
- 2-wire, 3-wire and 4-wire type, 4- wire type gives the most accurate measurement results
RTD is commonly used in the chemical industry and is suitable for the characteristics of the system Therefore, the group will choose RTD PT100 for the project
Figure 3.12: RTD PT100 RTD PT100 specifications:
To operate effectively at 60°C, degreasing chemicals necessitate the use of a signal converter, as the output from thermocouples or RTD PT100 is in analog form (mV or resistance), which the PLC S7-1200 can only interpret as a 0-10V signal Suitable transmitters for this application include various models designed to facilitate this conversion.
Table 3.4: Advantage and Disadvantage of some transmitters
- Anti-interference function, temperature compensation mode
After analyzing the advantages and disadvantages, both methods effectively detect mangoes on the conveyor belt However, the PR4114 kit includes unnecessary features for our project, leading us to choose the "A8H22 Temperature Transmitter" to save on investment costs.
3.4.4.3 Thermistor and Single-Phase Solid-State Relay
The group use thermistor to boil chemical liquid, and Single Phase Solid State Relay (SSR) to control it The specifications of these two are presented in the appendix section
Figure 3.15: Single-phase solid-state relay
To enable horizontal operation of the crane, section 3.2.1 mandates the use of an inverter for motor speed control, leading to various motor options available for selection.
Table 3.5: Advantage and Disadvantage of some motors
- Precise control of position and speed
- Limited speed and torque range
- Open-loop system Servo Motor
- Precise control of position and speed
- Wide range of speed control
Considering the advantages and disadvantages of various motor types, the position control feature found in Step Motors and Servo Motors may not be essential, as it introduces unnecessary complexity Consequently, the combination of a three-phase motor with a Variable Frequency Drive (VFD) emerges as the most efficient solution.
Based on the design requirements of the model, the horizontal crane operating motor is selected to satisfy the following conditions:
- Friction coefficient between wheel and rail: 3 1.2
Power of the engine to operate the crane: 20 0.5 0.012 12
Based on the results of the power just calculated, the group chooses Oriental Motor 4IK25GN-SW2/4GN36K engine as a motor for cranes
Figure 3.16: Oriental Motor 4IK25GN-SW2/4GN36K Oriental Motor 4IK25GN-SW2/4GN36K specifications:
Starting a motor directly from the power grid can lead to problems like shock and mechanical wear To address these issues, a Variable Frequency Drive (VFD) is utilized, providing a smooth motor startup and allowing for continuous start-stop cycles This approach not only reduces mechanical wear but also enhances the motor's lifespan and overall operating efficiency.
CHAPTER 3 HARDWARE DESIGN also saving energy during startup and operation Connecting the motor to the VFD allows for easy speed control and motor direction reversal, either directly through the VFD or via automated control systems
In section 3.3.2, the importance of selecting a VFD compatible with the RS422/485 communication module is highlighted, as this ensures stable and smooth product movement while minimizing vibrations.
Table 3.6: Advantage and Disadvantage of some VFDs
- Cost-effective and versatile VFD
- Compact design and easy installation
- User-friendly interface with clear display and navigation
- Good compatibility with various communication protocols, including RS485
- Limited advanced features compared to higher-end VFDs
- May have a narrower power rating range compared to other models
- Compact and cost-effective VFD
- User-friendly interface with clear display and navigation
- Good performance for basic motor control applications
- Limited advanced features compared to higher-end VFDs
- Smaller power rating range compared to other models
- May have limited communication options
The Siemens V20 and Schneider Electric Altivar 312 are both cost-effective and compact options within a limited power range While the Siemens Sinamics V20 may offer a more restricted feature set, it is ideal for small-scale model projects Additionally, it integrates seamlessly with the Siemens PLC S7-1200, enhancing its functionality within the same ecosystem.
Figure 3.17: VFD Siemens Sinamics V20 VFD Siemens Sinamics V20 specifications:
- Input voltage: Single-phase 220VAC
SOFTWARE DESIGN
Chapter Introduction
In this section, we explore the fascinating realm of software design, an essential component of the software development lifecycle Software design involves converting requirements and specifications into a coherent and organized system that ensures effective implementation and maintenance.
Design Requirements
The program must follow requirements:
- Locate crane stop by sensor
- Inverter to control motor speed for crean
- Control ON/OFF drying process
- Control the temperature of the chemical tank by PID tune
- Monitor the operating status of each device (motor, temperature, timer, etc)
- The system can be controlled by the HMI display, and the relevant parameters must also be displayed
- The system operates in 2 modes, automatic and manual
- The system displays alarms of failure and overload.
PLC Program Design
From design requirements, the state diagram of the software is shown in Figure 4.1:
Figure 4.1: The state diagram of the software
Figure 4.2: State diagram of automatic mode
Block 1 (idle block): After the system is powered on, it will enter a idle state, then we must select the control mode by the AUTO/MAN switch on the HMI
Crane go back Crane run
Block 2 (manual block): Operater can control the crane run left/right, go up/down through the system by HMI
Block 3 (auto block): In this block, the system can operate automatically, and data is collected and updated continuously This step includes four secondary block function:
The worker prepares the product on the crane by configuring the speed, dip time, and dry time on the HMI screen Once the settings are complete, they press the Start button to initiate the system, which then automatically proceeds to the next phase.
A chemical tank operates with an intact sensor that ensures the product is submerged in the chemical for a predetermined duration Once the process is complete, the product is lifted and advances to the next stage The temperature within the tank is regulated by a PID controller integrated into the PLC, with the initial temperature set at the beginning of the operation.
- Water tank: When the sensor is intact, the product goes down and lifts twice in the water tank When finished, the product goes to the next part
The dry process involves the product being subjected to heat, activated by a fan and light for a predetermined duration Once the process is complete, the product is directed to the drop area where a worker unloads it After unloading, the worker presses the End button, prompting the crane to return to its starting position.
Block 4 (error): When there is a problem or the system is overloaded, all operations will stop After the problem is fixed, the system will continue to operate in the previous state
This program is written in ladder language and uses sub-functions for its operation TIA portal V17 software is utilized to create this program
PID Control
Figure 4.3: Tune PID parameter of Tia Portal V17
The group implemented PID tuning in software by configuring hardware that included a sensor and thermistor within a tank Once the hardware was established, they initiated the PID tuning process in Fine Tuning mode and patiently awaited the system's completion.
The PID parameters derived from Auto Tuning may not always provide optimal system control To identify the most effective PID settings, the Ziegler-Nichols method serves as a valuable approach Empirical guidelines for tuning these PID parameters are outlined in the table below.
Table 4.1: PID parameters affect system dynamic
Rise time Overshoot Settling time SSE
Kp Decrease Increase Minor change
Ki Decrease Increase Increase Eliminate
HMI Design
The HMI design to control and monitor the system must follow requirements:
- Access permissions: Only authorized people can adjust the system manually, while workers can only adjust the system in automatic mode
- Manual mode: All devices can be controlled through HMI (Motors, ON/OFF dry process, etc)
In auto mode, users can easily operate the system using just the On/Off and Start/End buttons Additionally, the group can configure the dip and dry time settings at the beginning of the auto mode for optimal performance.
- Each process will have a malfunction indicator button and light
The project features three screens: the Cleaning Process Screen, Plating Process Screen, and Drying Process Screen However, due to project limitations, only the Cleaning Process Screen and Drying Process Screen are available for control and monitoring.
Based on the requirements, cleaning process screen is designed like the following figure 4.5
The control screen is essential for monitoring and managing the entire cleaning process, featuring buttons for adjustments such as up, down, run/stop VFD, forward, and reverse It displays critical parameters, including the engine speed in Hz, the temperature of the degreasing tank, and soaking time, ensuring clear visibility of operational metrics.
Based on the requirements, drying process screen is design like figure 4.6:
The monitoring screen serves as a central interface for overseeing and controlling the entire drying system, displaying key parameters such as drying time Both administrators and engineers have the capability to manually turn the process ON or OFF, ensuring efficient operation and management.
If any trouble occurs, the system alarm will be displayed along with a flashing yellow light
There are three accounts that can login to the system Each account will have its own specific privileges according to Table 4.2:
Table 4.2: Table of access permissions
Admin Full access to all functions
Engineer Full access to all functions
Employee Access to system operation in auto mode only
Figure 4.8: Parameter setting access interface
Figure 4.9: Login screen popup window
Smartphone Interface
On smartphone screen shown all button, switch, etc for control and diagram, chart, gause display all data of the system
The group can use smartphones to interface with the system through local network.
RESULT
Chapter Introduction
In this chapter, the results obtained on hardware and software will be presented.
Chapter Contents
Figure 5.1 depicts an overview of the model after it has been completely assembled
The model frame is made of steel, the tank is made of mica, the drying process uses a cooling fan and fluorescent lights
Figure 5.1: Hardware overview of the model
Figure 5.2 illustrates the crane's mechanism, highlighting the motor-driven horizontal movement of the trolley and the vertical lifting and lowering of the product facilitated by a pulley and chain system.
Figure 5.3 represents the front view of the electrical cabinet and the internal view of the cabinet
Figure 5.4: Overall view of the system model 5.2.2 Sofware
Figure 5.5: HMI Drying Process Screen
CONCLUSION & DEVELOPMENT
Conclusion
Implementing a PLC-controlled wastewater treatment system offers significant advantages, including time savings, reduced operating costs, and lower maintenance efforts This automated operation not only enhances efficiency but also allows for real-time monitoring and error detection, enabling the team to swiftly address issues and safeguard the system from potential damage.
Moreover, security and authorization functions make the system more secure, as well as being able to divide control functions for each object based on their qualifications (worker, engineer, supervisor…)
When developing a large system, careful attention must be given to the preparation stages, equipment selection, communication standards, methods, and associated modules This meticulous approach is essential for ensuring precision and skill, which helps to avoid operational errors.
After completing the project, the team recognized that each system has unique requirements influenced by environmental factors, material conditions, regional differences, and, most importantly, the specific needs of customers.
- Design, construct and control the cleaning and drying model
- The model can be controlled through HMI and smartphone
- Temperature control for chemical tank using PID
- Communication between PLCs (Master-Slave) used for control
- The load of the product is not the same as the original target
- Do not use real chemicals liquid
- There is only 1 common electrical cabinet for both PLCs (Master-Slave) and placed at cleaning process
- The system is not fully automated yet, as the steps of uploading and downloading still require human intervention
- The thermistor capacity is small, and it takes a long time to reach the set point temperature.
Future Development
In the future, the group can improve the system in many facets:
+ Divide at least 3 electrical cabinets for each process
+ Using three-phase motor for vertical motor operation
+ Make the model fully automation
+ The drying process adds a conveyor
+ Optimize the automation to make the system work more smoothly
+ Network communication to be able to send errors, overload signals through Webserver, Internet
+ Control temperature for the drying process by PID
It is essential to alert administrators and operators about potential errors and warnings, including temperature deviations, liquid level fluctuations, system malfunctions, and maintenance reminders, to ensure optimal system performance and prevent operational issues.
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[5] Dr-Ing N V Mandich, CEF, “Surface Preparation of Metals Prior to Plating” HBM Electrochemical & Engineering Co.2800 Bernice Road Lansing, Illinois
[6] NW PA Reg Plann and Dev Co, “Standard Guide for Cleaning Metals Prior to Electroplating”, IHS under license with ASTM, 2014
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