With the accelerated development of the concept of Industry 4.0 and intelligent manufacturing, and the rapid popularization of informatization and big data monitoring production methods, UV roller coating production automation is also accelerating the process transformation of the traditional roller coating industry with the advantages of high roller coating quality and high return on investment. . At this stage, most of the roller coating production in my country is mainly controlled by stand-alone equipment. Although there is on-line production, it does not have the function of joint control and joint adjustment of the whole line, which leads to high labor intensity of the workers. When the equipment fails, there is no linkage and interlocking. Downtime, resulting in high equipment damage rate and high maintenance costs. In addition, the changes in the human structure of today’s society have led to the difficulty of recruiting and the continuous improvement of wages, which has plagued the roller coating industry. To solve the above problems, it is necessary to consider the upgrade of automation and intelligence of the roller coating line, so as to improve production efficiency and product quality, and reduce operating costs.
In order to realize the centralized control of the UV production line and ensure the linkage and adjustment of the entire line, this scheme is formulated according to user requirements. In this scheme, there are a total of 15 sets of stand-alone equipment, including 2 dust collectors, 1 heavy-duty soil filling machine, 2 double-wheel coating machines, 2 double-lamp dryers, 1 triple-lamp dryer, and 5 conveyors. , 2 sanding machines. Among them, the sanding machine is a self-purchased product by the user and is included in the control scheme of this system. The sanding machine needs to provide a communication control interface for the control of the system.
Figure 1 On-site electrical cabinet (partial)
3. Control system and network configuration
1. PLC adopts Ikondrives brand, optional Ethernet interface, bus communication adopts industrial Ethernet for communication, communication protocol MODBUS/TCP protocol, fast transmission speed, strong real-time control, each stand-alone device selects the corresponding model according to the actual number of points and needs PLC.
2. In principle, the conveyor is not equipped with PLC control, and is included in the nearby equipment for control. Therefore, the PLC system of the nearby equipment should reserve the control interface of the conveyor to reduce the cost of bus control.
3. In order to improve the reliability and stability of the system, as well as data processing capability, communication rate, etc., this system uses a high-end PLC as the master control PLC to process all data.
4. The stand-alone equipment of this system is equipped with a man-machine interface for monitoring, and any stand-alone machine can be controlled and adjusted on the spot.
5. The total monitoring system adopts a 10-inch touch screen and PLC for monitoring, and can also be configured with Haiwell cloud box (CBOX) + large screen controller (TVBOX) + (large screen) solution to achieve centralized control. In this system, cloud box is selected. +The scheme of the large-screen controller, the master control system has the function of cloud control, which can perform remote debugging programs, and the mobile phone can remotely monitor the equipment status and other functions.
6. The network communication adopts 12-16-port industrial Ethernet switch, the network cable adopts industrial grade shielded Ethernet communication cable, and the switch needs to be installed in a special electric box. When installing on site, the network cable needs to be routed through iron pipes or independent wire grooves. Improve anti-interference ability.
Figure 2 System networking
Four, process control system function
(1) Conventional functions of process system
1. The bus control system has the functions of memory and formula. When producing different products, the formula of different products can be directly called. The formula includes parameters such as setting speed and height. The formula call can be used to measure the plate thickness through the product thickness gauge at the entrance of the production line, and then confirm that the data is saved to the corresponding formula, and it can be called when this type of plate is produced.
2. With the linkage of the whole line, one-key start and stop, when starting, the terminal equipment is started first, and then the front-end equipment is started one by one in sequence, and the order of stopping is just the opposite. Avoid the impact on the power grid caused by simultaneous startup.
3. When there is a faulty machine, the conveying equipment of the faulty machine towards the entrance should be stopped immediately, but the roller coating wheel will not stop, and will rise to a safe height by itself, and the equipment will maintain normal operation in the direction of the exit. After the fault is reset, it will automatically drop to the setting. high. The fault types are divided into conveying faults, card board faults, dimmer faults, inverter faults, limit over-limit alarms, etc.
4. When linked, you can control the running or non-running (disabled) of any roll, and rise to a safe height.
5. The UV dryer adopts an electronic light source, which can adjust the light source steplessly. It runs at full power when there is a board, and runs at 30% power when it is in standby without a board. It can also adjust the power of the light source in real time. The data after fine-tuning the height of the on-site lifting can be directly transmitted to the master control PLC after being saved, and saved and memorized in the recipe, which is convenient for the next call.
6. A set of material detection device is installed at the entrance of the production line as the basis for the system operation and standby state switching. This set of devices also serves as a plate thickness detection alarm signal. When the plate thickness exceeds the set thickness, a switch signal is sent to The total control PLC will give an alarm and stop the conveying.
7. Install a detection device on the dryer to determine whether the dryer is stuck or not, and stop immediately after the jam to avoid fire accidents.
8. Due to the long production line when the whole line is controlled, a three-color indicator light is installed on each machine to better monitor the running status of the whole line, green running, yellow standby, and red fault.
9. The background monitoring system has functions such as equipment running status monitoring, fault alarm information display, one-key start and stop functions, production statistics, recipe setting and calling, user login and logout, etc.
Figure 3 On-site production line
(2) Functions of energy management
1. The dryer of this system is equipped with an electronic dimmer. The dimmer can adjust the frequency conversion speed of the cooling fan according to the power of the light source, so as to achieve the purpose of energy saving and consumption reduction.
2. Each roller of the roller coating machine is equipped with a paint weighing device and a gap adjustment device between the rubber wheel and the steel wheel. The weighing device can monitor the paint weight in real time. Lower limit alarm and other functions. In addition, the amount of paint can be indirectly judged by adjusting the gap between the steel wheel and the rubber wheel, thereby converting the paint consumption.
3. Each device can be installed with a smart meter, or a smart meter can be installed on the entire line to monitor the power consumption of each shift every day, so as to monitor the behavior of saving electricity.
4. For forward and reverse roller equipment, the reverse roller lift automatically adjusts the lifting height according to the position of the plate to ensure that the plate does not hit the roller when it enters the reverse roller, because when the reverse roller hits the roller, the paint is piled up and falls on the conveyor belt, which affects the equipment. Hygiene and maintenance, while also reducing paint loss.
(3) Functions of equipment maintenance
1. The electronic dimmer is equipped with a running time record. When the UV lamp reaches the use time, an alarm prompts to replace the lamp tube for equipment maintenance.
2. Use the solenoid valve of the oil supply roller as the timing basis to judge the use time of each rubber roller, so as to remind the user when to change the roller, so that the equipment can be better maintained.
V. Summary of the plan
1. Ikondrives cloud box (CBOX)/HMI has all the functions of Ikondrives cloud platform. Through Ikondrives cloud, this system can realize cloud monitoring, intelligent management, support remote access control of mobile phone terminal/computer WEB terminal, and has strong operability. When the master control system is connected to the Internet, it can realize the remote monitoring function and monitor the production data in real time. The Ikondrives cloud platform has the cloud alarm function. When the system generates an alarm, the alarm information can be pushed to the mobile APP in real time, and the operation of the equipment can be understood in real time. status, and deal with equipment failures in a timely manner.
2. Ikondrives Cloud Box (CBOX)/HMI supports MQTT data reporting function, which can upload data to mainstream databases such as Mysql/SQLserver, connect to ERP/MES system, and realize the production information management of enterprises.
3. The system supports Ikondrives cloud platform. Ikondrives cloud platform has built-in Ikondrives cloud engine and cloud management functions. Through Ikondrives cloud engine, remote PLC program upload and download, monitoring, firmware upgrade and PLC diagnosis can be realized; through Ikondrives cloud management, It can realize remote upload and download of HMI/CBOX projects, firmware upgrade and historical data export.
4. Ikondrives cloud platform adopts A/B key security access mechanism. The host and administrator manage the equipment at the same time, and the audit mechanism is used to manage the access rights of remote access personnel. Safe and secure.
5. Ikondrives PLC 485 communication supports simultaneous communication with different baud rates, different protocols, and different data formats. The communication program does not need to deal with the timing sequence, which greatly saves the engineer’s programming time, especially in the setting frequency of multiple frequency converters on the roller coating machine. , The processing of signals such as operating frequency and operating current has obvious advantages.
6. The Ethernet PLC is selected on site. The Ethernet PLC supports simultaneous access by multiple upper computers. At the same time, the Ethernet port can also be used as the master station to access other devices, which can be master and slave, which is convenient for debugging.
7. Ikondrives large-screen display (TVBOX) can realize the function of electronic signage, support 4-grid, 6-grid, 9-grid multi-screen display, and can display multiple HMI/CBOX/IPC in the local area network on one large screen at the same time The interface of an HMI/CBOX/IPC can also be displayed on a large screen alone, and the traditional electronic signboard function can be realized with a relatively economical solution.
Figure 4 Mobile APP monitoring interface
Figure 5 The communication program between the main control PLC and two stand-alone equipment PLCs through Haiwellbus
Figure 6 CBOX screen development interface 1
Figure 7 CBOX screen development interface 2