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Bottle in the PLC control lubricating oil automatic filling machine application and design
2020.02.04

Summary:Bottle lubricating oil filling system design application of the FX series of small PLC, designed for the characteristics of the bottle lubricating oil control filling, to complete the bottle lubricating oil empty bottle disinfection, handling, lubricating oil filling, encapsulation of the cap as well as the sealing test and other procedures, to complete the entire automatic filling machine work process.

0 Introduction

A few years with the continuous development of the domestic and foreign economy, the lubricant industry also set off a high-speed development of the boom, all kinds of products are constantly updated. In order to meet market demand, which makes the lubricant production enterprises continue to improve the production technology and process, and the traditional lubricant filling automatic filling machine electrical equipment control system is generally the traditional relay - contactor control mode, in the process of use, low productivity, man-machine dialogue rely on the "indicator + button + speaker" way of working, slow response, high failure rate and poor reliability, can only be based on the experience of the passive Can only passively check the working status of the system by experience, dealing with faults, monitoring and maintenance of equipment, and in the production process is prone to secondary pollution, resulting in low product qualification rate and increased production costs.

With the development of industrial automation, automated automatic filling machine came into being, that is, by the workpiece delivery system and control system will be a group of automatic machine tools and auxiliary equipment in accordance with the process sequence linked up to automatically complete all or part of the manufacturing process of the product production system. The application of PLC in the field of industrialized automatic production also makes the automated automatic filling machine more complete, easier to control. Because PLC itself has a powerful arithmetic operation, timing, counting, logic control, sequence control, storage and other functions, it can not only control all kinds of systems through the digital quantity and quantity, but also through the Ethernet and the host computer communication, field bus and intelligent equipment communication, better complete the production task.

In this paper, for the production characteristics of bottled lubricant filling, combined with industrial bottled lubricant filling automation specifics, the application of PLC to the design of bottled lubricant filling, in this automatic filling machine can be completed in the lubricant bottle clean disinfection of empty bottles, empty bottles handling, lubricant filling, cap bottles, and bottles of lubricant sealing detection, detection is complete, after the qualified products are packed, and non-qualified products to be recycled. Recycling.

1 metering filling machine introduction

Bottled lubricant filling mainly involves the key links, including lubricant bottle disinfection and cleaning, lubricant filling, lubricant bottle sealing, sealing detection and storage of bottled lubricant packaging. According to these requirements the liquid filling machine process is divided into, the cleaning and disinfecting place of empty bottles, robotic handling device, automatic filling assembly line and qualified products crating place, qualified products will be transported to the VI for crating, 12 bottles for a box, unqualified lubricants are directly launched for recycling.

The filling equipment collects and controls the data on the site, and the filling equipment is in the site control layer, and the filling system realizes collecting and controlling all kinds of signals on the site, and its main functions are as follows: communicating with the upper computer system, collecting and transmitting the information of the filling machine by the filling system; collecting the analog input signals of the liquid level, frequency of the frequency converter and so on on the line; collecting the switching status signals of the pumps, solenoid valves, photoelectric switches, proximity switches and electric Real-time collection of pumps, solenoid valves, photoelectric switches, proximity switches, electric actuators and other switching status signals, and according to the operating requirements of the output signals to control a variety of valves on and off; and then communicate with the weighing and filling machine, so that the weighing and filling device to control servo motors to achieve accurate control of the canned capacity; and ultimately to achieve automatic control of the system.

2 lubricating oil automatic filling machine working principle

Liquid filling production line consists of filling machine, capping machine, sealing machine, coding machine, the entire production line by the conveyor belt throughout, responsible for the delivery of containers. Filling machine is the main equipment of this production line, and its performance plays a decisive role in the function and efficiency of the whole production line. In order to improve the performance of the filling machine, filling designed by the servo control system, step control automatic filling machine system, programmable controller (PLC), human-machine interface, conveyor belt frequency control system, pressurized pneumatic part and photoelectric sensors and other components of the machine, gas, electricity integrated automatic control system.

Liquid filling machine using programmable logic controller (PLC) S7-300 and automatic weighing and filling machine as its control body. Filling scale in the hardware connection, PLC as a control system in the lower computer, and a variety of underlying equipment in direct contact. PLC filling system and the upper computer communication, access to product information and production parameters, as well as based on a variety of sensors in the production line, the control of filling head of the logic of the action, control the speed of the filling conveyor belt, weighing and filling machine to drive stepper motors to control the adjustment of the filling head, to achieve the two-dimensional positioning and filling of the inlet baffle precision positioning; based on the PLC to give out the automatic filling volume, the filling machine is the main body of control. Precise positioning of the inlet baffle; according to the PLC to give the automatic filling volume, the completion of the servo drive and liquid filling capacity compensation, drive the pressurized hydraulic cylinder action, to achieve the adjustment of the filling capacity, and at the same time through the compensation algorithm calculated by the compensation of the volume of information, to join the adjustment of the filling capacity.

3 PLC selection and specific address allocation

Filling system used Mitsubishi FX2N series small PLC, which has a small form, high speed, high performance and other characteristics, the control scale of 16 ~ 256 points, can be applied to a number of basic components of the connection between the control, control, positioning control and so on. Connecting the expansion unit or expansion module on the basic unit, it can carry out the flexible input and output combination of 16~256 points, and there are several available simple instructions in the soft component application instructions, high-speed processing instructions, variable input filtering constants, interrupt input processing, direct output, etc., which facilitates the data reading of the commanded digital switches, the reading of 16-bit data, the reading of the matrix input, the output of the 7-segment display, and so on. According to the control requirements of this design, the explosion-proof filling machine used to 21 inputs, 24 outputs, the distribution of PLC inputs and outputs of the ground.

3.1 Data acquisition and servo control system

Automatic filling device in order to accurately control the filling volume, the design of the position servo control system to accurately control the stroke of the piston cylinder, but also to achieve precise control of the filling volume.

Metering filling machinery filling liquid temperature, viscosity changes caused by volume changes caused by quality fluctuations, liquid filling machinery is a non-linear relationship between the acquisition of liquid viscosity, temperature, pressure, through certain compensation algorithms, to achieve the piston cylinder stroke compensation, to receive the position command signal from the PLC, the PLC metering filling device given position and the compensation position is superimposed on the position of the position as a total given After the position signal is regulated by the composite feed-forward controller in the position loop, the speed command signal is formed, and the deviation signal after comparing the speed command signal with the speed feedback signal is regulated by the proportional-integral controller in the speed loop to generate the current command signal, which is converted into a vector in the current loop, and then the torque current is output by SPWM to control the operation of the AC servo motor. The position control accuracy is controlled by the number of pulses generated by the rotary encoder per revolution.

3.2 Touch screen system

The design of the filling machine is also installed on the touch screen and metering filling system PLC communication, for parameter setting and operation status of the field display. ADP7.0 (screen editing software provided by HITECH) is used to design the whole system screen. The main screen is the default screen of the touch screen, and the corresponding sub-screen is accessed by each function button to monitor the system; a number of function buttons are set on the manual screen to manually operate each action of the system; at the same time, the function buttons are set to open other screens, and the sub-screen is the same; the start button on the automatic screen is used to automatically start the system, the emergency stop button is used to stop the system in case of emergency, and the reset button is used to stop the system when a fault occurs, and the reset button is used to reset the system. The reset button is used for system reset and alarm lifting after the fault is lifted, and a number of indicator lamps are set to show the system's operation status; the fault display screen shows various fault alarm signals, and the fault display screen pops up immediately when the system fails, with the latest faults lined up on the top and arranged from top to bottom according to the time of the occurrence of the early and late, and the information scrolling display can be controlled by the up and down buttons when the screen is full.

4 PLC part of the program design

Programmable logic controller software, in accordance with the workflow of the production line, the use of its specialized programming software, the use of ladder diagram form of the production line control program, and written into the programmable logic controller, to achieve the overall control logic of the production line and the production function; in the metering of the filling machine software, the preparation of the capacity of the calculation and the servo system control program; the network control part of the computer (upper computer) and the lower computer (PLC), in which the computer as the upper level of the control system to achieve the plant's multiple filling machine control and management, mainly for managers. The network control part includes a computer (upper machine) and lower machine (PLC), in which the computer as the upper layer of the control system, to achieve the control and management of the plant's multiple filling machine, specifically for managers, mainly for the change of filling containers as well as generating, printing and management of the production line of a variety of reports to show the production line's operating status, once the fault, to the administrator to report in time to the administrator, the weighing of the liquid filling machine when necessary, managers can be Through the server to remotely stop and start the operation of the production line.

5 Conclusion

PLC as a controller applied to industrial automation, the use of its design and control of filling with a high degree of automation, reliability and other advantages, can better fulfill a variety of filling functions. This project by simplifying the complex bottled lubricant filling in the current factory, the application of Mitsubishi FX2N series PLC design and production of a bottle lubricant filling, completed the entire industrial process.


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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