Design and implementation of enhanced surface cleaning and drying process for metal plating system

MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS AUTOMATION AND CONTROL ENGINEERING TECHNOLOGY DESIGN AND IMPLEMENTATION OF ENHANCED SURFACE CLEANING AND DRYING PROCESS FOR METAL PLATING SYSTEM LECTURER: ASSOC PROF NGO VAN THUYEN STUDENTS: BUI QUOC HUY DOAN TRONG NAM SKL 011317 Ho Chi Minh City, July 2023 MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING -⸙∆⸙ - GRADUATION THESIS DESIGN AND IMPLEMENTATION OF ENHANCED SURFACE CLEANING AND DRYING PROCESS FOR METAL PLATING SYSTEM STUDENT 1: BUI QUOC HUY ID: 19151082 STUDENT 2: DOAN TRONG NAM ID: 19151064 SCHOOL YEAR: 2019 MAJOR: AUTOMATION AND CONTROL ENGINEERING TECHNOLOGY INSTRUCTORS: ASSOC PROF NGO VAN THUYEN Ho Chi Minh City, July 2023 MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING -⸙∆⸙ - GRADUATION THESIS DESIGN AND IMPLEMENTATION OF ENHANCED SURFACE CLEANING AND DRYING PROCESS FOR METAL PLATING SYSTEM STUDENT 1: BUI QUOC HUY ID: 19151082 STUDENT 2: DOAN TRONG NAM ID: 19151064 SCHOOL YEAR: 2019 MAJOR: AUTOMATION AND CONTROL ENGINEERING TECHNOLOGY INSTRUCTORS: ASSOC PROF NGO VAN THUYEN Ho Chi Minh City, July 2023 GRADUATION PROJECT ASSIGNMENT THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness Ho Chi Minh City, June 30th , 2023 GRADUATION PROJECT ASSIGNMENT Student name: Bui Quoc Huy Student ID: 19151082 Student name: Doan Trong Nam Student ID: 19151064 Major: Automation and Control Engineering Technology Advisor: Assoc Prof Ngo Van Thuyen Class: 19151CLA Phone number: 0935 342 223 Date of assignment: 26/02/2023 Date of submission: 30/06/2023 Project title: Design and Implementation of Enhanced Surface Cleaning and Drying Process for Metal Plating System Initial materials provided by the advisor: - Visit company - Structure and Operation of Metal Plating System - Apply communication Content of the project: - Design and build electrical cabinets - Communication between PLCs - Communicate with VFD by USS - Applied PID method for control temperature - Interface with HMI - More knowledge about chose quipments Final product: The complete Enhanced Surface Cleaning and Drying Process for Metal Plating System model CHAIR OF THE PROGRAM (Sign with full name) GRADUATION THESIS ADVISOR (Sign with full name) Page | i ADVISOR’S EVALUATION SHEET THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness Ho Chi Minh City, July , 2023 ADVISOR’S EVALUATION SHEET Student name: Bui Quoc Huy Student ID: 19151082 Student name: Doan Trong Nam Student ID: 19151064 Major: Automation and Control Engineering Technology Project title: Design and Implementation of Enhanced Surface Cleaning and Drying Process for Metal Plating System Advisor: Assoc Prof Ngo Van Thuyen EVALUATION Content of the project: - The content of the project is adequately rigorous in terms of academic level and engineering practice for a bachelor thesis in automation and control discipline - The thesis structure follows a standard form that demonstrates how the thesis question was formulated and solved Strengths: Theory and prototypes were presented to evaluate the engineering design The engineering design considered the limitation in term of budget and the duration for the thesis Weaknesses: The prototype does not cover all stages of a complete process control system Approval for oral defense? (Approved or denied) Approved Overall evaluation: (Excellent, Good, Fair, Poor) Good Ho Chi Minh City, July , 2023 ADVISOR (Sign with full name) GRADUATION THESIS Page | ii PRE-DEFENSE EVALUATION SHEET THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness Ho Chi Minh City, July , 2023 PRE-DEFENSE EVALUATION SHEET Student name: Bui Quoc Huy Student name: Doan Trong Nam Student ID: 19151082 Student ID: 19151064 Major: Automation and Control Engineering Technology Project title: Design and Implementation of Enhanced Surface Cleaning and Drying Process for Metal Plating 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, July , 2023 REVIEWER (Sign with full name) GRADUATION THESIS Page | iii THANK YOU THANK YOU We would like to express my sincere gratitude to all those who have contributed to the completion of this thesis Without their support, encouragement, and guidance, this work would not have been possible We are truly grateful for their invaluable contributions First and foremost, we would like to extend my deepest appreciation to our supervisor, Assoc Prof Ngo Van Thuyen, for his unwavering support and guidance throughout the entire research process His expertise, patience, and insightful feedback have been instrumental in shaping this thesis We are grateful for his continuous encouragement, motivation, and belief in our abilities Furthermore, we are indebted to the faculty members of High Quality Engineering Department, especially Mrs Nguyen Tran Minh Nguyet – the program chair of the Automation and Control Engineering Technology at Ho Chi Minh City University of Technology and Education, who have contributed to our academic growth and provided a stimulating learning environment Their dedication to teaching and research has been truly inspiring Lastly, but certainly not least, we would like to extend our appreciation to friends and colleagues who have supported us throughout this journey Their encouragement, insightful discussions, and willingness to lend a helping hand have been invaluable Thank you STUDENTS Bui Quoc Huy Doan Trong Nam GRADUATION THESIS Page | iv ABSTRACT ABSTRACT The graduation thesis project “DESIGN AND IMPLEMENTATION OF ENHANCED SURFACE CLEANING AND DRYING PROCESS FOR METAL PLATING SYSTEM” has the primary task to design and build the system for metal plating industry The aim of this thesis is to design a metal cleaning and drying system that can address the remaining issues of the existing system To meet practical requirements such as monitoring operational processes and verifying the correct functioning of equipment, as well as checking if the temperature of the chemical tank is suitable for metal plating This system displays real-time information on a control panel, allowing operators to promptly identify any deviations and make appropriate decisions for problem resolution Moreover, the system is designed to provide timely error notifications when equipment malfunctions occur, as well as control and monitor the temperature of the chemical tank to prevent the production of defective products Additionally, certain functions within the operation process are secured between the admin (team leader, manager, etc.) and Operator (operating staff) through the User Administration feature, ensuring the system's overall security and access control GRADUATION THESIS Page | v LIST OF CONTENTS LIST OF CONTENTS GRADUATION PROJECT ASSIGNMENT i ADVISOR’S EVALUATION SHEET ii PRE-DEFENSE EVALUATION SHEET iii THANK YOU iv ABSTRACT .v LIST OF CONTENTS vi LIST OF FIGURES viii LIST OF ABBREVIATIONS xi CHAPTER OVERVIEW 1.1 Introduction 1.2 Surface Cleaning of Metal Plating 1.3 Topic Goal 1.4 Topic Limit 1.6 Project Contents .5 CHAPTER THEORETICAL BASIS 2.1 Chapter Introduction .6 2.2 Technological Process 2.3 Cleaning Methods 2.4 Test Methods for Cleaniness 11 CHAPTER HARDWARE DESIGN 12 3.1 Chapter Introduction .12 3.2 Chapter Contents 12 3.2.1 Design Requirements 12 3.2.2 Technical Process .13 3.3 Block Design 14 3.4 Select Device 15 3.4.1 Controller Block (PLC) 15 3.4.2 Supervisor Block 18 3.4.3 Sensor Block .21 3.4.4 Temperature Block 23 3.4.5 Crane Block 27 GRADUATION THESIS Page | vi LIST OF CONTENTS 3.4.6 Drying Block 32 CHAPTER SOFTWARE DESIGN 33 4.1 Chapter Introduction 33 4.2 Design Requirements .33 4.3 PLC Program Design 33 4.4 PID Control 36 4.5 HMI Design 37 4.5.1 Screen Hierarchy .38 4.5.2 Alarm 39 4.5.3 Access 40 4.6 Smartphone Interface 41 CHAPTER RESULT 42 5.1 Chapter Introduction 42 5.2 Chapter Contents 42 5.2.1 Hardware 42 5.2.2 Sofware .44 CHAPTER CONCLUSION & DEVELOPMENT 46 6.1 Conclusion 46 6.1.1 Topic Done 46 6.1.2 Limitation of Topic 46 6.2 Future Development 47 REFERENCE 48 APPENDICES 49 GRADUATION THESIS Page | vii CHAPTER CONCLUSION & DEVELOPMENT - 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 6.2 Future Development In the future, the group can improve the system in many facets: - Hardware: + Build the plating process + Divide at least electrical cabinets for each process + Make more cranes + Using three-phase motor for vertical motor operation + Make the model fully automation + The drying process adds a conveyor - Sofware: + 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 + To provide warnings to the admins and operators about as much as possible errors and warnings that may occur such as temperature deviation, liquid level, system malfunction, maintenance reminders, etc - HMI: + More detailed decentralization + HMI for plating process GRADUATION THESIS Page | 47 REFERENCE REFERENCE [1] “Chromium Plating”, American Galvanizer Association, https://galvanizeit.org/hot-dip-galvanizing/how-long-does-hdg-last/chromiumplating [2] “Metal Plating Market Size, Share & Trends Analysis Report" , Grand View Research, Inc https://www.grandviewresearch.com/industry-analysis/metal-platingmarket [3] “Metal plating market report”, Dataintelo,https://dataintelo.com/report/metalplating-market-report/ [4] Dinh Long, “An Overview of Vietanmese steel industry 2014”, Vietnam’s Steel Sector Insights, http://www.vssi.com.vn/2015/01/an-overview-of-vietnamesesteel.html?m=0 [5] Dr-Ing N V Mandich, CEF, “Surface Preparation of Metals Prior to Plating” HBM Electrochemical & Engineering Co.2800 Bernice Road Lansing, Illinois 60438, 2002 [6] NW PA Reg Plann and Dev Co, “Standard Guide for Cleaning Metals Prior to Electroplating”, IHS under license with ASTM, 2014 [7] “Quy trình mạ crom”, Cơng Ty TNHH Cơng Nghiệp Đình Long, https://dinhlong.com.vn/quy-trinh-ma crom#:~:text=Quy%20tr%C3%ACnh%20c%E1%BB%A7a%20h%E1%BB%87%2 0th%E1%BB%91ng,%E2%86%92%20r%E1%BB%ADa%20%E2%86%92%20l% C3%A0m%20kh%C3%B4, 2022 GRADUATION THESIS Page | 48 APPENDICES APPENDICES Appendice 1: PLC Programming - PLC Master: GRADUATION THESIS Page | 49 APPENDICES GRADUATION THESIS Page | 50 APPENDICES GRADUATION THESIS Page | 51 APPENDICES GRADUATION THESIS Page | 52 APPENDICES GRADUATION THESIS Page | 53 APPENDICES GRADUATION THESIS Page | 54 APPENDICES GRADUATION THESIS Page | 55 APPENDICES - PLC Slave: GRADUATION THESIS Page | 56 APPENDICES GRADUATION THESIS Page | 57 APPENDICES Appendice 2: Wiring diagram GRADUATION THESIS Page | 58 APPENDICES GRADUATION THESIS Page | 59 APPENDICES GRADUATION THESIS Page | 60