MINISTRY OF EDUCATION AND TRAININGHO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS MAJOR: MECHATRONICS ENGINEERING TECHNOLOGY INSTRUCTOR: TUONG PHUOC THO DANG QU
OVERVIEW AND THEORICAL BASIS
Introduction to modern production lines, control, monitoring, maintenance and
In the era of rapid technological advancements, the application of communication systems across various industries is vital for meeting production and automation needs This is particularly evident in the bottled water production and packaging line, which utilizes a closed and continuous operation system to guarantee consistent product quality and hygienic safety.
Effective communication systems in industrial environments are essential for the operation, monitoring, and control of production processes and components They ensure stable operations and adherence to standards throughout the product creation process.
To ensure the stability of production lines during continuous operation, it is essential to keep equipment and machinery in optimal condition Implementing a comprehensive monitoring and maintenance plan for all system components is crucial for achieving peak performance in operational processes.
The industrial communication system integrates various technologies and equipment to efficiently collect, process, and transmit data within the manufacturing environment Essential components include sensors, automatic control systems like PLCs and HMIs, drive systems such as conveyors and motors, and electrical cabinets that provide power and protect automatic control systems or variable frequency drives Additionally, robots are vital for executing and processing continuous stages of production.
An automated industrial production line is created by integrating communication protocols among sensors, PLCs, robots, conveyors, and variable frequency drives These interconnected components function harmoniously, ensuring efficient operation under the oversight of designated personnel or managers.
The automatic control system of the water bottle packaging line, utilized in the Industrial Robot and Sensors practice course, previously faced instability and limited performance between stations However, through targeted improvements and upgrades, the system is now designed to operate more continuously and smoothly, enhancing overall efficiency.
MECHANICAL DESIGN
Overall about the system
Designing and installing a hardware structure requires detailed drawing and simulation of the system These drawings allow for a clear understanding of how components fit together, enabling the design of precise additional elements This approach not only enhances accuracy but also saves time and costs, making it far superior to relying solely on testing without a defined prototype.
Figure 2: The water bottle system
The system operates sequentially from left to right, with the bottle initially moving to Station 1 At this station, a cylinder halts the bottle to allow a sensor to detect any defects.
If a defect is detected in the bottle, the alternate cylinder activates to push it to Station 2; otherwise, the cylinder remains off, allowing the bottle to proceed At Station 3, the box is transported to the end of the conveyor, where it triggers a sensor that activates an actuator with two double-cylinders to push it through to Station 4 Once at Station 4, the box stops to wait for the bot to pick up six units.
18 bottles from Station 1 Finally, the box is transport to the taping system, and finish the process at the end of station 4
The automatic water bottle packaging system is designed for educational purposes, allowing students to learn and practice using a real model This hands-on experience enables them to effectively apply the knowledge they have acquired in a practical setting.
The system utilizes Siemens S7-1200 PLCs to effectively manage the operations of each station Additionally, each station is equipped with a Samkoon HMI screen, allowing students to program and control the stations seamlessly through the user-friendly interface.
In the control system, every station is connectted like the picture above, it all includes PLC S7-1200, a converter SINAMICS V20 by Seiment, buttons, sensors, solenoids, cylinders and motor to control conveyor
Here are the specifiactions of the components:
PLC Siemens S7-1200 1214C AC/DC/RLY
Figure 2.1: PLC Siemens S7-1200 1214C AC/DC/RLY
Number of Outputs 10 (Digital Output, Relay Output)
Number of Inputs 14 (Digital Input, 2 switch as Analogue
For Use With SIMATIC S7-1200 Series
Communication Port Type Ethernet, Profinet, UDP
Mounting Type DIN Rail, Wall Mount
Programming Language Used FBD, LAD, SCL
Figure 2.2: Module SB 1232, AQ 1x12bit
Output range -10V to +10V/0 to 20mA
Maximum Current 300mA PNP normally open
Standard Detection Object Sunlight 10000LX or less Incandescent lamp 3000LX or less
Figure 2.5: Cylinder JELPC DN20x75/DN16x125
Operation Single acting or double acting
Mountings Basic LB FA FB SDB
Operating Speed Range 50 to 800 mm/s
Operating Pressure Range 0.1 to 0.9 MPa
Operating Speed Range 100 to 500 mm/s
Effective Cross Section Area 16mm² (CV=0.89)
Port Size Inlet, Outlet ＝ G 1/4″ , Exhaust Port ＝
Working Medium 40 Micron Filtered Air
Power Consumption AC: 3.5VA; DC: 2.5W
Wiring / Connector Cable / Lead Wire or DIN Connector
Figure 2.9: HMI Samkoon SK-102HS
Touch Panel 4-wire high-precision touch panel
Memory 128MB FLASH + 128MB DDR3
Protection Rating IP65 (front panel)
FCC Compatibility Complies with FCC, Class A
CE Certification Complies with EN55032 and EN55035 standards
Serial Interfaces COM1 and COM2 (RS232/422/485)
Network Connectivity No for WiFi, Yes for Ethernet, No for 3G,
No for 4G Operating Temperature -20°C to 55°C (no freezing)
Operating Humidity 5% to 95% RH (no condensation)
Shock Resistance 10-25Hz (XYZ direction, 2G for 30 minutes)
Field Bus Communication Type Modbus RTU, USS
Applicable Load IC circuit, Relay, PLC
Power Supply Voltage 5, 12, 24VDC (4.5 to 28 VDC)
Current Consumption 10mA or less
Load Voltage 28VDC or less
Load Current 40mA or less
Internal Voltage Drop 1.5V or less (0.8V or less at 10mA load current)
Leakage Current 100àA or less at 24VDC
Indicator Light Red LED illuminates when turnd on
Electromagnetic Brake Induction Motor 41K25GN-SWM
Figure 2.13: Electromagnetic Brake Induction Motor 41K25GN-SWM
Motor Frame Size 3.15 in sq
Rated Torque 1.63 [200 VAC, 50 Hz]lb-in
Rated Speed 1300 [200 VAC, 50 Hz]rpm
Hardware connection of PLC Siemens S7-1200 1214C AC/DC/RLY and inverter
Hardware connection of PLC Siemens S7-1200 1214C AC/DC/RLY
24 VDC Sensor Power Out.For additional noise immunity, connect "M" to chassis ground even if not using sensor supply
For sinking inputs, connect "-" to "M" (shown) For sourcing inputs, connect "+" to "M"
Connector pin locations for CPU 1214C AC/DC/Relay (6ES7 214-1BG40-0XB0)
Hardware connection of Inverter SINAMICS V20
Figure 2.16: General diagram of the inverter
Power Supply 10V 10V Supply output voltage 10V
Analog Input AI 1 Analog input channel 1, supports analog value from -10V to
AI 2 Analog input channel 2, supports analog value from 0V to
Analog Output AO 1 Analog output channel 1, supports analog value from 0mA to 20mA
Pin 0V 0V Pin 0V is used for analog channel and RS485 communication
Digital input DI 1 Digital input pin, supports
Source and Sink connection Operates in the voltage range 0V-30V
Voltage > 11V is level 1, voltage Warm Start to Reset the
Robot to update the previous system change status
Figure 6.5: Restart Robot to upload data
After restarting the Robot, the statuses have been updated, we proceed to configure the Name, IP and I/O for the Robot through the Configuration - I/O Configuration section
To set up a new IP address for the Profinet network, navigate to the IP settings section, right-click, and select "New." This action will prompt a small window where you can enter a name for the new IP configuration.
Here I have set the name and address for the IP setting as PROFINET Network and 192.168.0.20 Create the default Subnet for Profinet as 255.255.255.0
In the Interface section, select LAN3 port
Figure 6.7: Add IP Address and Subnet with Interface LAN3
After restarting the system, the next step is to select the device type for the I/O System Navigate to the I/O System and choose the PROFINET Device In the Device section, select the Device Catalog for installation configuration, and choose Internal BASIC V1.2.
Figure 6.8: Type of internal device with description
Figure 6.9: Choose the appropriate internal device
Figure 6.10: PN_Internal_Device Module DI/DO 64
Upon finishing the selection of DI/DO modules, we will generate Digital Signals for both DI and DO modules This process can be executed directly within the I/O Configuration section or through the I/O System - Signal section in the main interface.
To create a New Signal, navigate to the I/O Config section and name the signals in the Signal Editor The software will automatically configure the corresponding modules, signal types, and mapping numbers in a top-to-bottom order Remember to click "Write Config" to restart the system and update the configuration with each new Robot setup.
After establishing a network connection between the PLC and the Robot's Internal Device, proceed with the operational steps Integrate the DI/DO module into the system, ensuring the selection of the appropriate 64-byte DI/DO modules.
Figure 6.13: Choose the appropriate DI/DO module for internal devices
The I address and Q address displayed here will be in the order corresponding to the define section mapped in RobotStudio Suppose we choose I address from 68-131 corresponding to DI/DOs with device mapping from 0-63 For Q address is 2-65
Then we create a Tag Table, with data type Bool and an address corresponding to the order of the mapping section on RobotStudio
After finalizing the necessary steps, we compile and upload the program Next, to establish the connection protocol, it is essential to assign the robot's Profinet IP address to the PLC.
In this section, we will focus on the "Function – Assign Profinet device name" to establish the Profinet protocol connection between the Robot and the PLC Upon successful assignment, the signal will indicate a green status, signaling the commencement of Profinet communication between the PLC and the ABB Robot.
Figure 6.14: Assign PROFINET device name to connect with PLC