Application of Network Control Technology in Vulcanizer Control System

The vulcanizer control system adopts network control. Guilin Rubber Machinery Factory mentioned it around 1995. At that time, it could not be realized due to the limitation of the programmable logic controller (hereinafter referred to as PLC) network system and various reasons. In view of the various defects of the recording controller mentioned above, at present, many tire factories at home and abroad, such as South China, Guiyang, Jiaozuo, Yinchuan, Giti, Santai, Sumitomo, etc., have adopted network control technology. The earlier network control system was limited by the technical conditions at that time, and the number of vulcanizing machine consoles was greatly limited. At present, we have designed and produced the network control system of the vulcanizer, which can control up to 156 units. The number of the vulcanizer consoles is generally related to the control system of the vulcanizer.

Rockwell Automation/Allen-Bradley (AB) Network Systems(Allen Bradley 1756-CN2R Communication Module, Allen Bradley 1794-IRT8 Thermocouple RTD Input Module, B&R X20BT9100 X2X Link Bus Transmitter, B&R X20DO9321 Digital Output Module)

It adopts a three-layer structure:

(1) Ethernet is used in the information layer for data acquisition and program maintenance of the whole plant.

(2) Adopt control network, DH+, DH485 and remote I/O in the automation and control layer to realize real-time I/O control, controller interlock and message transmission.

(3) The device network is used at the device layer for low-cost and high-efficiency information integration of the underlying devices.

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Application of PLC, DCS and FCS in metallurgical process control

In metallurgical production, the process control system completes the detection, display, recording, adjustment, control, alarm and other functions of the generated process parameters. play an extremely important role. Its characteristic is to control the real-time production process, the control process is complicated, the process lags behind, there are many monitoring parameters and data changes, and the data processing and storage volume is large. According to the characteristics of the process control system and the control requirements of different production processes, the application of different control systems can complete the production tasks in a safe, reliable and cost-effective manner. At present, domestic advanced large and medium-sized process control systems basically adopt PLC and DCS. ( Siemens 6ES7331-7KF02-0AB0 SIMATIC S7-300 Analog Input Module, B&R X20do6322 Digital Output Module, Allen Bradley 1756-PB72 Power Supply Module, Siemens 6ES7331-7NF10-0AB0 Analog Input Module) The following briefly analyzes the different application characteristics and selection principles of PLC, DCS and FCS in the process control of small and medium-sized metallurgical production. Features of various control systems :

1. The main characteristics of the PLC system are: reliable operation, fast operation speed; building block structure, flexible combination; good compatibility; simple and rich programming and generation; strong network function. The PLC system can well complete industrial real-time sequence control, condition control, counting control, step control and other functions; it can complete 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: complete functions; network communication technology; complete open system; high reliability;

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

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Consider the technical serviceability of the system manufacturer

At present, in China's PLC system and DCS sales market, foreign manufacturers have a large share. Major foreign manufacturers are generally in China's high-energy product promotion and technical service agencies, while foreign companies often undergo reorganization, mergers or mergers. The structure, sales strategy, and market share direction are all different. After the merger or merger, there will be changes in the technical promotion and services in the Chinese market, some will be strengthened and some will be weakened. Therefore, when we choose a system, we should Fully grasp the information and consider the technical serviceability of the system manufacturer to protect the advancement and development of the selected system and ensure sufficient technical support and spare parts supply.

B&R X20PS9400 Power Supply Module,  Siemens 6ES7361-3CA01-0AA0 SIMATIC S7-300 Interface Module, B&R X20PS4951 Power Supply, Siemens 6ES7365-0BA01-0AA0 SIMATIC S7-300 Interface Module

To sum up, the principles of system selection can be considered from the following aspects: system scale, complex procedures, system integrity and communication performance, as well as manufacturer technical support and after-sales service. In the metallurgical production process control system, it is of great significance to ensure the automation level of the production process control system and reduce the project cost according to the complexity of the process objects and the reasonable selection of different control systems for the reliability of the control system.

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It is 2023 now. I wish you a happy new year 2023

Looking back on 2022, we have experienced a lot, though there`s some losses, but more gains.

I sincerely wish every customer more gains in 2023.

Thank every customer for their preference for our products and their trust and support for our company in 2022.

We hope that in 2023 we can continue to strengthen cooperation.

2023, let's join hands to create happy and healthy wealth, thank you.

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How the system working

Use a volumetric tube to calibrate the flowmeter. In order to accurately reflect the repeatability of the meter at each flow point, according to the national standard GB/T13282, the basic volume of the volumetric tube should be selected according to the following principles: 

In the formula: VQ——basic volume design value (m 3 ); Qmax——upper limit value of the tested flowmeter (m 3 /h);like below

ProSoft MVI56E-MNET Modbus TCP/IP Interface Module，Siemens 6ES7332-7ND02-0AB0 SIMATIC S7-300 Analog Output Module, Allen Bradley 1761-NET-AIC Advanced Interface Converter, Siemens 6ES7340-1AH02-0AE0 SIMATIC S7-300 Communications Processor

As long as this principle is met, the running speed of the elastic ball can be guaranteed to be less than 3 m/s, and the more economical running is within the safe speed range.

In order to ensure the reliability of the calibration, before the official calibration, the tightness test of the volume tube system should be carried out: first conduct the test process, and then the control system starts the booster pump to pressurize the volume tube system to maintain the pressure in the volume tube If the pressure before the inlet valve is 0.5 MPa, observe for 30 minutes. If the pressure drop is less than 0.2 MPa, calibration can be carried out.

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Processing of power supply by PLC 

Power supply is one of the main ways for interference to enter the programmable controller. Power supply interference is mainly generated by impedance coupling of power supply lines, and various high-power electrical equipment is the main source of interference.

In situations with strong interference or high reliability requirements. A shielded isolation transformer and a low-pass filter can be added to the AC power input( Allen Bradley 1794-IB16 Flex Input Module, B&R X20BM05 Bus Module, Siemens 6ES7132-4BD02-0AA0 ET 200S Electronic Module,  Allen Bradley 1734-OB8 Output Module) end of the programmable controller (see Figure 1). The isolation transformer can prevent external interference from the power line. To improve the ability to resist high frequency common mode interference, the shielding layer should be grounded reliably.

he external DC power supply for the external input circuit should preferably be a stable power supply. The power supply that only rectifies and filters the AC voltage contains strong ripples, which may cause the programmable controller to receive wrong information.

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Programmable Controller Periodic Maintenance

As a kind of industrial control equipment, programmable logic controller(Allen Bradley 1756-PA72 ControlLogix, Allen Bradley 1756-RM Enhanced Redundancy Module, B&R X20CP1584 CPU, Allen Bradley 1756-L61 ControlLogix Controller) is widely used in all walks of life due to its high reliability. However, due to the working environment and other peripheral equipment and some problems of its own, it takes time every six months to one year. Regular inspection and maintenance of the PLC system to ensure the normal operation of the system. The specific inspection items, content and PLC requirements are shown in the table below.

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Reasons for ammonia blocking denitration spray gun-chapter 2

Ammonia blocking the spray gun may be caused by the following reasons

Phenomenon: One is left or right.

Reason for.

A. The fan control hole on the side of the air cap is blocked

B. The air cap is damaged. When using ammonia spray gun, it is necessary to spray corrosive reducing agent to the area between 850 ℃ and 1050 ℃ in the boiler furnace, so it is necessary to use corrosion-resistant and high-temperature materials.

Solution.

A. Clean atomizing cap

B. Replace the atomizing cap.

Phenomenon 2: the center of spraying amplitude is too thick. The processes of SCR and SNCR denitrification systems are not very different, except that the SCR reaction temperature is lower than that of SNCR due to the use of catalyst. However, from the perspective of construction cost and operation cost, SCR investment is at least several times, or even more than 10 times, that of SNCR. (Allen Bradley 1769-IQ32 Compact I/O Module, B&R X20A04622 Analog Output Module, Allen Bradley 1769-PA4 CompactLogix Power Supply)

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Software process

Practical application

After the system was installed and debugged, it was officially put into use in October 1999. It has been running stably for more than two years and has calibrated nearly a hundred flowmeters (times) without any problems in the control system. 

Practice has proved that the system has a high degree of automation, and all performance indicators fully meet the design requirements. 

The PLC control system cooperates with the volumetric tube system, which makes the system have high calibration accuracy, avoids the error caused by human operation, and greatly improves the reliability. 

B&R X20AI1744 I/O Module

Siemens 6ES7331-1KF01-0AB0 SIMATIC S7-300 Analog Input Module

Allen Bradley 1756-A4 Four Slots Chassis

Siemens 6ES7331-1KF02-0AB0 SIMATIC S7-300 Analog Input SM 331

The display screen of the system is rich and intuitive, the operation interface is simple and friendly, and it is easy to use. The workload of the operator is reduced, the work efficiency is greatly improved, and good results are achieved.

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Software and hardware configuration of the control system

(1) Hardware part

① Industrial computer IPC

In order to ensure the high reliability of the system, Advantech IPC610 industrial computer is selected. The specific configuration is: PIII800MHz CPU, 128M memory, 40G hard disk, MAG17-inch flat-panel display, graphics card with 64M video memory, sound card and speakers (for alarm and prompt), etc.

②PLC _ (Siemens 6ES7314-6CG03-0AB0 CPU 314C-2 DP Compact CPU, Allen Bradley 1734-OE4C Analog Output Module, B&R X20AI4622 Analog Input Module, Siemens 6ES7314-6EH04-0AB0 SIMATIC S7-300 CPU 314)

The Modicon MicroTSX3722 PLC of French Schneider Company is selected as the control core of the system. It is small in size, powerful in function and good in scalability. The specific configuration is as follows:

Host: Micro TSX3722 (built-in power supply, CPU)

Analog input (AI) module: TSXAEZ802 is selected, it has 8 high-level analog input terminals, can input standard signals such as 0-20 mA, 4-20 mA, 12-bit A/D conversion accuracy, and has input overshoot monitoring Function and measurement filter anti-interference function;

Analog output (AO) module: choose TSXASZ200, it has two analog output terminals (one common terminal), no external power supply, can output various standard signals, including 0~20 mA, 4~20 mA, ±10 V Wait.

Digital input (DI) module: choose TSXDEZ12D2, which has a schematic diagram of the system structure in Figure 2-1　　

Digital output (DO) module: TSXDSZ08R5 is selected, it has 8 relay outputs, internally provides overload and short circuit protection, and has channel fault self-diagnosis function;

High-speed counting (HSC) module: choose TSXCTZ2A, which has two counting channels, which can count two pulses with a maximum frequency of 40 kHz at the same time, and can realize up-counting, down-counting or up/down counting.　　

Communication (CMM) module: select TSXSCP114PCMCIA card (supporting TSXCM4030 serial connection cable), connect to IPC with TSXSCA50 connector, realize bidirectional data transmission and exchange between PLC and IPC, and the communication protocol is MODBUS.

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