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Design of fully automatic control system for liquid filling machine
2020.02.17

Summary:The liquid filling machine is operated through the Proface touch screen and connects the entire weighing system through pressure components and metering modules. Contactors and intermediate relays control solenoid valves and low-pressure actuators, including switches, pumps, mixers, pneumatic ball valves, finished liquid batching tanks, etc. .

Liquid silicone filling industry modern industry widely used in the filling management problems proposed a new automatic filling machine development model, and the use of Mi crosoft's high-level computer language VB6.0 and general-purpose database Access2000 and SI-EMENS weighing controller PLC combined to develop the composition of the metering data filling system. This dosing and filling machine is not only capable of recording, storing, viewing and archiving measured values on a computer and other management functions, but also performs industrial process control. Quantitative filling machine PLC communicates directly with the RS485 port, or configure analog input and output modules configured for use, weight indicator and PLC to perform the production process control, the program can be compiled as a stand-alone file or installation file to facilitate the use and migration. This paper describes the development of this liquid filling machine as an example for presentation purposes.

The automatic filling machine is controlled by a weight indicator, a low-voltage actuator motor in a liquid level module, and other controls, including a dosing tank level switch, a pump, a stirring motor, a discharge pneumatic ball valve, and a finished liquid dosing tank. The development of the liquid filling machine is relatively mature in accordance with the various requirements of the control process. To facilitate filling control, the host section designed using Ethernet software, collecting and displaying field data, synchronizing and updating distributed information, and implementing filling control. Liquid filling machine is is to realize the automation of the production process, intelligent, scientific management of enterprises, safe and reliable production, energy saving and saving consumption of important technical means. Automatic filling machine using the weighing module and speed weighing will be in the weight of the material passing through and motor speed converted to electrical signals, two sets of converted signals through the field button box through the A/D conversion transmitted to the main weight indicator table, in the calculation, adjustment, appropriate control value output D / A conversion is transmitted to the frequency converter, the control of motor operation in the process can be achieved through the required tons of material per hour, the control of the Filling cumulative measurement results are sent to the weight indicator, uploaded by the DCS to the filling system's industrial control machine.

Traditional control software provides a DDE server or OPC by default, and real-time data can be accessed and analyzed by developing client software that meets the needs of the filling system. A sample program provided by a generic supplier was written using VB and the DDE real-time data collection method was selected in WinCC. Similarly the field filler uses two servers and a field client model to store the collected data in Excel. The liquid filling machine uses unpacked timed backup software to periodically back up the data to a data backup server through the data collection server. Each client has WinCC monitoring software installed that is responsible for data display, archiving, querying, transferring between classes, clearing fields, etc. As long as one is familiar with Excel, Excel's VBA programming can be used to collect field data from the PLC into the filling system for automatic statistics, data analysis, aggregation, and so on. In the weighing and filling machine, the key part of the control is Siemens S7-200, Ethernet control of filling and dosing, Ipc is responsible for collecting input signals and sending control commands to the actuator after the program. The weight indicator and the host computer are connected through a communication cable. When the input signal is sent to the weight indicator table, the PC acquires the data via Ethernet and displays it at the same time.

In order to further reduce the difficulty of operation by one-feed manpower, a touch screen can be considered instead of the existing control buttons. Filling control in remote control mode is used for all applications in production, i.e. in the configuration software interface. Liquid filling machine through the Proface touch screen operation, contactors and intermediate relays to control each solenoid valve and motor, thus simplifying commissioning and maintenance. The Liquid Filler has weighing modules, pressure transmitters, level meters, position switches for pneumatic valves, and gas supply pressure gauges for detecting and monitoring the working conditions. Multi-channel transfer must be done by controlling three-way valves through the touch screen to select the filling equipment for the purpose of filling the individual filling drums during the transfer, and the method of control is divided into a manual mode and an automatic mode. The process of each link is more or less the same, there is no extra control link.

Multi-station liquid filling machine
The field management and control system of liquid filling machine based on single chip microcomputer, radio frequency card and network integration technology can control the filling of materials in real time and effectively. Realize the real-time detection of filling weight and the real-time opening and closing of solenoid valve in filling process, and upload data for effective microcomputer management.
Application of liquid pumping and mixing batching system
The batching system adopts dual CPU to form a redundant system, and the STEP7MicroWin V4.0SP6 programming software provided by Siemens is used as the man-machine interface to write debugging programs and download programs. The PC and PLC experimental machine are connected by a PC/PPI cable for communication, and the corresponding parameters are set.
Automatic liquid filling machine function application
Automatic liquid filling machine is controlled by frequency converter to realize stepless speed change, set the target weight, easy operation and fast filling speed, adopting large and small feeding and filling methods, optional computer connection or real-time printing of filling parameters such as filling date, serial number, net weight, tare weight, cumulative weight and so on.
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