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Application and selection of PLC.DCS.FCS in automated batching system
2020.03.12

Summary:The weighing and batching system completes the functions of detecting, displaying, recording, adjusting, controlling, and alarming generated process parameters, and plays an extremely important role in improving the operation rate of automated production lines, improving product quality, and shortening the development cycle of new products and new processes.

Automatic dosage system to complete the generation of process parameters detection, display, recording, adjustment, control, alarm and other functions, improve the operation rate of automated production lines, improve product quality and shorten the development cycle of new products, new technologies play an extremely important role. It is characterized by real-time production process control, complex control process, process lag, monitoring parameters and data changes block, data processing and storage of large quantities. According to the characteristics of the feeding system and different production process control requirements, the application of different weighing and feeding system can be both safe, reliable and cost-effective way to complete the production task. At present, the domestic advanced large and medium-sized quantitative dosage system basically to use PLC and DCS-based, the following briefly analyzes the PLC, DCS and FCS in the industrial automation of the production process control of different application characteristics and selection principles, the characteristics of various dosage systems:

1, PLC feeding system is mainly characterized by: reliable operation, fast running speed; building block structure, flexible combination; good compatibility; programming and generation of simple, rich; network function. PLC system can well complete the industrial real-time sequential control, conditional control, counting control, stepping control and other functions; able to complete the analog/digital (A/D), digital/analog (D/A) conversion, data processing, communication networking, real-time monitoring and other functions.

2, DCS has the following main features; full-featured; network communication technology; complete open system; high reliability; comprehensive and professional; the realization of human-machine dialogue technology; flexible system expansion; strong management capabilities.

3、FCS mainly has the following characteristics: highly decentralized structure of fully automatic batching system; strong interoperability; validity and integrity of data; controllability; high security; flexible expansion.

As the fieldbus FCS automated batching system is still in the development stage, the standard has not been unified, the equipment manufacturers are in a wait-and-see state, the existing bus standard intelligent equipment prices are obviously high (such as 20,000 yuan for the transmitter). Iron and steel industry has fewer regulatory circuits, monitoring parameters, the characteristics of the fieldbus FCS speed dosage system application is less, some applications are also used as a remote terminal of the PLC system, generally using Profibus bus. Here mainly introduces DCS and PLC atmospheric pressure batching equipment selection.

PLC and DCS in the process of seizing the market, the two draw on each other, penetration, integration, greatly increasing the user's selectivity in the design and use. At the same time, due to a variety of vertical dosage system production manufacturers, product replacement fast, but also to the system selection brings some difficulties. Now based on the different characteristics of PLC systems and DCS, in the industrial automation construction and transformation projects, the metering and dosage system design selection and application of the following principles of selection summarized.

1, according to the spiral batching control scale and complexity

Different automation production process, isobaric dosage control scale and complexity is different, usually in the positive pressure dosage of larger scale, higher degree of complexity of the DCS is preferred, because the system is based on the characteristics of the development of the vacuum dosage, it is a large number of analog data information can be better processed, analyzed, calculated to complete a variety of complex, cumbersome regulation and control of calculations, and therefore be able to complete the scale of the large, High complexity of the negative pressure batching work.

2, according to the scale of investment and project economic efficiency reasonable choice

In some small and medium-sized automation projects, especially small and medium-sized transformation projects, less investment, smaller instrumentation and control system should be given priority to choose the price is relatively low modest, cost-effective PLC system. Such as in 1991, JISCO a steel 3 # slab continuous casting machine two cold water renovation project and plate plant heating furnace renovation project and other projects in the design, according to this principle in the spiral dosage system selected TI-545 series PLC system, but also achieved very good results.

3, consider system continuity, compatibility and communication performance

In some automation projects, such as the original project has a computerized dosage system, it is necessary to consider the continuity and compatibility of the system. If the transmission dosage system occupies a large proportion, it is necessary to consider the connection with the production management computer system information network that communication performance. 2005, the first set of computerized dosage system - MODICON584 series PLC in the JISCO ironworks 4 # blast furnace charging system application was successful in the future of the ironworks blast furnace renovation or construction, due to the consideration of the MODICON production PLC products have strong compatibility and communication performance, the use of MODICON series PLC products (first 584 series, and later more advanced 984 series and Quantum series) on the blast furnace system control or upgrade the system, to ensure that the system's advancement, continuity, compatibility, and to facilitate the information of the blast furnace system between the communication links and ironmaking production management network. Communication links and iron production management network construction, reducing the control software configuration repeat tedious labor, reducing the inventory cost of spare parts.

4, considering the technical services of explosion-proof system manufacturers

Currently in China's PLC systems and DCS sales market, foreign manufacturers have a large share of major foreign manufacturers in China generally high energy product promotion and technical service organizations, and foreign companies often reorganization, merger or consolidation, due to the product structure of the company, sales strategy, market share of a different direction, merger or consolidation, in the Chinese market, technical promotion and service, there will be some Therefore, when we choose the system, we should fully grasp the information and consider the technical service of the system manufacturer, so as to protect the advancement and development of the chosen system, and to ensure the supply of sufficient technical support and spare parts.

To sum up, the principle of speed batching system selection can be considered from the following aspects: system size, complex program, the system's inexpensive capacity and communication performance, as well as the manufacturer's technical support and after-sales service. In the automated production of weighing automatic dosage system, according to the process of object complexity of different, as well as for the quantitative automatic dosage of the reliability of the reasonable choice of different automatic dosage, to ensure the production of dosage automation level, reduce the cost of the project has a very important significance.

PP20130623205227
CS Automatic dosage system
The dosage system and weighing instrument realize serial communication based on the development environment. The data from the weighing instrument is sent to the host computer in real time through the serial port, and the read data is intercepted and converted, and the weighing data can be displayed in real time on the operation screen, and at the same time, the weighing data can be stored in the database for querying and tracing the data, which is not only convenient to supervise the weighing process, but also to restrain the worker's operation. The upper computer software of automatic dosage system is designed with PLC program. The WINDOWS-based upper computer software has the functions of real-time process monitoring, overweight/overtime alarm, alarm processing, automatic data saving, querying historical data, printing formula and historical data. The feeding system adopts the rotating feeding basket installed on the screw to receive the materials, which effectively solves the problem that the feeding time in the whole production time accounts for too large a proportion in the dosing program of the lined-up dosing system. The weighing terminal from the signal to rotate to the receiving position is only 2 baskets apart, which is much faster than the receiving speed, and is conducive to improving the efficiency of the entire system. Sequential pick-up method, so that each recipe of small materials in a set order of cascade, so that the process personnel can easily identify the weighing of small materials and troubleshooting in parallel. The dosage weighing device adopts silo screw machine, the material flows to the mixer through the silo, each mixer has two weighing modules, and connected to the junction box, a speed weighing module, the signals through the junction box to the weighing instrument, and then by the dosage weighing instrument will be analog signals and pulse signals to the PLC, PLC processing output signals to the computer to monitor the operation of the PLC will be the computer commands to the weighing instrument for processing. The PLC will transmit the commands from the computer to the weighing instrument for processing. Batching scales and electrical interlocking, can be set from the computer flow, control to the dosage of dosage scales, can be switched through the "switch" button to switch the control, the frequency of dosage is the computer through the PLC to the frequency converter communication to control the output of the frequency converter, so as to change the rotational speed of the silo screw, in accordance with the required amount of dosage of dosage scales. The weighing flow setting at the weighing terminal is set by calculating the required value and outputting it to the PLC, then inputting it to the dosage weighing instrument and adjusting the frequency of the silo screw machine after PID calculation in order to achieve the required amount of material to be discharged.
Weighing and mixing machine in powder dosage system application program
The whole automatic batching system consists of industrial control machine, PLC, industrial weighing instrument, frequency converter, vibration motor, mixer, sensor, conveyor belt and other parts.
Powder Dosing System Design
The automatic dosage system consists of an industrial grade control computer, programmable controllers, and electrical control boxes, and is designed to meet the needs of a maximum number of silos and platform scales for mixing, weighing, and mixing control.
Screw dosage system technology application
Screw automatic dosage system is the ideal equipment for continuous dosage and measurement of bulk materials, which can set high, middle and low feeding, and then control the feeding speed of screw feeder, so as to achieve the purpose of accurate dosage. According to the actual process of batching process, it reflects the operation status of feeding, batching, feeding and related equipment in the form of dynamic screen.
Application Design of Weighing Mixer
Weighing and mixing machine through PLC to control the frequency converter, so that the speed motor drives the metering screw according to the set speed running down the material. The whole weighing and dosing system can be divided into small material weighing, large material weighing and micro material weighing. It adopts the way of uniform speed feeding, and the way of decreasing speed feeding is adopted in the low speed stage.
Automatic Powder Batching System
Batching system in the field of powder processing and treatment, the leading technology of powder processing equipment absorbed and optimized in the weighing and mixing machine in accordance with the production instructions and formulas, a variety of materials will be placed, transported to the set station, using automatic walking weighing mechanism, a variety of materials accurately and proportionally added to the barrel.
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