Industrial Automation Using B&R PLC.
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The document discusses the automation of a draw frame machine using B&R PLC to reduce costs associated with conventional models. It outlines the machine's functions, including input and output configurations, operational modes, and programming aspects, aimed at increasing efficiency and affordability for Indian customers. Additionally, it highlights the transition from a microcomputer system to a PLC setup, showcasing the potential savings of approximately 1.25 lakh Rs.
![B&R PROGRAMMING MODULES
Cyclic Program #1-[10ms]
• Input Initialization
• Output Initialization
• Variable Initialization
• Manual Mode Service Program
• Auto Mode Service Program
• Program for Working Mode
Cyclic program #2-[10ms]
• Program for warning
• Program for bitmap
• Program for password
• Program for reset
Cyclic program #3-[50ms]
• Program for date and time
• Program for key and led test](https://image.slidesharecdn.com/plcautomation-130928110205-phpapp01/85/Industrial-Automation-Using-B-R-PLC-25-320.jpg)
Industrial Automation Using B&R PLC.
- 1. AUTOMATION OF DRAW FRAME MACHINE USING B&R PLC Prepared By: Prof. Sandeep J. Rajput Assist. Prof., EC Dept. HCET,Sidhpur.
- 2. INTRODUCTION • This presentation is about Automation of Draw Frame Machine using B&R PLC. • The machine which makes the strong sliver by twisting the number of thin cotton threads feeds from the cans of feed creel is called Draw Frame machine. • This machine is a substitution of the conventional draw frame machine to reduce the cost. • The Yarn material produced by conventional draw frame is of higher cost which all the customers can’t afford. • In order to reduce the cost of the fabric material to satisfy the customers in cost with almost same quality the machine is used. • This new approach has lower cost because it uses less component compare to the conventional draw frame machine . • Main aim of is approach to add Indian customer specific features & reduce the cost of TMS-2 system and NOM3 relay module which used in control panel by replacing B&R PLC.
- 3. SCHEMATIC BLOCK DIAGRAM OF CONTROL PANEL OF DRAW FRAM MACHINE
- 4. COMPONENT LAYOUT OF CONTROL PANEL 1: TMS, Trutzschler micro-computer system 2: Key switch for service mode 3: Power supply servo module 4: Rotary can plate drive servo module, SM10 5: Rotary sliver feed creel drive servo module, SM10 6: Delivery drive servo module, SM20
- 6. INPUT CONFIGURATION PORT:0&1 INPUT APPLICATION RELATED COMPONENTS E0.0 FUSE MONITERING FUSE F010,F030 E0.1 SAFETY LOOP O.K. NOM3 A200 E0.2 SAFETY EQUIPMENT OK NOM3 A200 E0.3 MOTOR PROTECTION SWITCH MPCB Q100,Q115,Q120,Q130 E0.4 EMERGENCY STOP SELECTION SWT S210,S250 E0.5 SAFETY LIMIT SWITCH PROTECTIVE HOODS SAFETY SWITCH S230,S240 E0.6 COMPRESSED AIR O.K CHANGE OVER CONTACT B5 E0.7 PRESSURE MONITORING,CENTRAL SUCTION CHANGE OVER CONTACT B570 E1.0 DRAFTING SYSTEM CLOSED SENSOR B436 E1.1 E1.2 E1.3 DRAFTING SYSTEM COVER CLOSED SAFETY SWITCH S450 E1.4 DRAFTING SYSTEM LAP 2-SENSOR A440,A441 E1.5 MONITORING O.K. SENSOR B431 E1.6 DELIVERY ROLLS O.K. SENSOR B433 E1.7 COILER PLATE AREA OK SENSOR B432
- 7. INPUT CONFIGURATION PORT:2&3 INPUT APPLICATION RELATED COMPONENTS E2.0 NO SLIVER BREAK SENSOR B468,SENSOR B467 E2.1 NO SLIVER BREAK SENSOR B466 E2.2 NO SLIVER BREAK SENSOR B465 E2.3 NO SLIVER BREAK SENSOR B463,B462,B461,B464 E2.4 3WAY KEYBOARD START/THREADING STARTA 520 E2.5 3WAY KEYBOARD INCHING MODE TIP A520,TIP A510 E2.6 3WAY KEYBOARD START START 510 E2.7 3WAY KEYBOARD STOP STOPA520,STOPA510 E3.0 SERVICE SWITCH (SERVICE OFF) NOM3 A200 E3.1 EXTERNAL EMERGENCY STOP E3.2 E3.3 TURNSTILE POSITION SENSOR B106 E3.4 CAN STOPPER EXTENDED SENSOR B131 E3.5 EMPTY CAN AVAILABLE SAFETY LIMIT SWITCH S110 E3.6 START CAN FEEDWAY DRIVE SAFETY LIMIT SWITCH S132 E3.7 CAN MAGAZINE IS FULL SAFETY LIMIT SWITCH B109
- 8. OUTPUT CONFIGURATION PORT:0&1 OUTPUT APPLICATION RELATED COMPONENTS A0.0 ENABLING SAFETY EQUIPMENT SAFETY LIMIT SWITCH S230,S240 A0.1 ENABLING IMPULSE SAFETY EQUIPMENT NOM3 A200 A0.2 A0.3 A0.4 FLASH LAMP WARNING CC CHANGING FLASH LAMP YELLOW H581 A0.5 SIGNAL LAMP NORMAL MODE (GREEN) SIGNAL LAMP GREEN H580 A0.6 SIGNAL LAMP WARNING (YELLOW) SIGNAL LAMP YELLOW H580 A0.7 SIGNAL LAMP FAULT (RED) SIGNAL LAMP RED H580 A1.0 A1.1 LOAD DRAFTING SYSTEM SOLENOIED VALVE Y3 A1.2 THREAD WEB GUIDE SOLENOIED VALVE Y1 A1.3 A1.4 LOAD TOP ROLL (SLIVER CUT) SOLENOIED VALVE Y6 A1.5 A1.6 A1.7
- 9. OUTPUT CONFIGURATION PORT:2&3 OUTPUT APPLICATION RELATED COMPONENTS A2.0 FAN IN FRAME CLOCKWISE RELAY K040 A2.1 FAN IN FRAME COUNTERCLOCKWISE RELAY K041 A2.2 CONTROL CABINET FAN RELAY K003 A2.3 SUCTION FAN ON RELAY K120 A2.4 SUCTION FLAP CENTRAL SUCTION SOLENOIED VALVE Y571 A2.5 A2.6 A2.7 A3.0 A3.1 A3.2 A3.3 TURNSTILE DRIVE CLOCKWISE RELAY K116,RELAY K115 A3.4 TURNSTILE DRIVE COUNTERCLOCKWISE RELAY K116,RELAY K115 A3.5 CAN STOPER EXTENDED SOLENOIED VALVE Y5 A3.6 CAN FEEDWAY DRIVE RELAY K130 A3.7
- 10. MODES OF OPERATION Working mode • In working mode the machine does all the routine work for which it was programmed . As the inputs are provided to the PLC the output is taken from it. There are basically 16 inputs & 16 outputs provided in the PLC. If more are needed than we can also use the expansion module. • In this mode there are sensors which sense the inputs and provide them to the PLC through which we can get the output. There are a total of nine sensors for doing the work. • The basic function of the machine is to count, even & uncurl the raw slivers that are provided to the machine. The input slivers are provided to it from the carding machine which is used to take the dust out from the cotton. • Multiple number of slivers are provided to the machine through the feed crill. All of these slivers are than compressed into one sliver by the drawing process. After this the slivers are carried out where they are stored in the bucket in the form of output.
- 11. MODES OF OPERATION Service mode • Within the scope of servicing, the current condition & the functionality of components are assessed. Whatever maintenance & repair work is necessary is determined from this condition. • In this operating mode we can select & test individual components. In some cases additional information is seen, such as rotary speeds, connections or the corresponding sensors. We can activate the service mode through the B&R PLC • Now for selecting the component to test we can select any of it by pressing the enter button on the PLC. The components which we can test are Motors M003, M004, M115, M120, and M130. Valves Y1, Y3/Y6, Y5, Y6, Y571. Sensors A460…A468, B431, B432, B433, B436, S110, S132, S230, S240, S450. L.E.D. RED, YELLOW, GREEN. • All the defective components after the service mode are to be replaced by the new ones. The other components which are up to date should be cleaned perfectly. Then the machine should be fully assembled back as it was before. We can manually or automatically service the machine through the service mode.
- 12. PROGRAMMING FLOW GRAPH OF SERVICE MODE VIA B&R PLC B & R
- 13. MAIN MENU FLOW GRAFH
- 14. VALVE TEST FLOW GRAFH
- 15. MOTOR TEST FLOW GRAFH
- 16. DRIVE TEST FLOW GRAFH
- 17. SENSOR TEST FLOW GRAFH
- 18. LED TEST FLOW GRAFH
- 20. 1. MODE SELECTION MACHINE MODE SELECT 1 = Go for Working Mode TD 02_MODE 0/1 0 = Go for Test Mode WORKING/TEST=1/0 2. AUTO_MANUAL TEST MODE 1 = Go for Auto mode TD 02_MODE 0/1 AUTO/MANUAL=1/0 0 = Manual Mode 3. GO TO 0. MOTOR TEST 5.I/P STATUS F1 Auto_manual 1. VALVE TEST 6.O/P SATUS 2. DRIVE TEST 7. D & T 3. SENSOR TES 8. RESTART F2 Auto_manual 4. SPECIAL TES 9. WARNING
- 21. 4. MOTOR SELECTION MOTOR 003 F1 GO TO MOTOR 004 MOTOR 115 MOTOR 120 MOTOR 130 F2 GO TO 5 .VALVE TEST VALVE Y1 F1 GO TO VALVE Y3 VALVE Y5 VALVE Y6 VALVE 571 F2 GO TO 6. SENSOR TEST B132 S450 F1 GO TO B431 S110 B432 S230 B433 S240 B436 F2 GO TO
- 22. 7. INPUT STATUS I/P1 I/P6 F1 GO TO I/P2 I/P7 I/P3 I/P8 I/P4 I/P9 I/P5 I/P10 F2 GO TO 8. OUTPUT STATUS O/P 1 O/P 6 F1 Go TO O/P 2 O/P 7 O/P 3 O/P 8 O/P 4 O/P 9 O/P 5 O/P 10 F2 GO TO 9. DATE & TIME DATE DD/MM/YYYY F1 GO TO **/**/**** TIME: HH/MM/SS **/**/** F2 GO TO
- 23. 11. RESTART MODE *** Restart Mode *** F1 GO TO 1. Restart Target : 0 2. Erase all Data and Restart Target : 0 F2 GO TO To come out of hanging situation of LAP COMMANDER, Without Switching off the Main Switch , if you want to start the target then make Restart target = 1. 2nd is 1 then it will Erase all set parameters and retentive data. After it all the parameterization will be done again. 12. WARNING MOTOR 003 F1 GO TO MOTOR 004 MOTOR 115 MOTOR 120 MOTOR 130 F2 GO TO
- 25. B&R PROGRAMMING MODULES Cyclic Program #1-[10ms] • Input Initialization • Output Initialization • Variable Initialization • Manual Mode Service Program • Auto Mode Service Program • Program for Working Mode Cyclic program #2-[10ms] • Program for warning • Program for bitmap • Program for password • Program for reset Cyclic program #3-[50ms] • Program for date and time • Program for key and led test
- 26. BLOCK DIAGRAM OF SIMULATOR Power Supply Relays Power Terminal Switch Mode Power Supply MCB Power Motor Protection Circuit Breaker PLCOutput Lamps Input Push Buttons Power Switch Input Port Output Port Power Supply MCB Contactor
- 27. DIGITAL I/P ASSIGNMENT Terminal No. Address Description 01 - (0V DC) 02 + (24V DC) 03 I1 Not used 04 I2 To start sensor B431 05 I3 To start sensor B432 06 I4 To start sensor B433 07 I5 To start sensor B436 08 I6 To start sensor s110 09 I7 To start sensor s230 10 I8 To start sensor s240 11 I9 To start sensor s450 12 I10 To select Auto/manual 13 I11 Warning in M130 14 I12 Not used 15 I13 Not used 16 I14 Not used 17 I15 Not used 18 I16
- 28. DIGITAL O/P ASSIGNMENT Terminal No. Address Description 01 - (0V DC) 02 + (24V DC) 03 Q1 To Start M003 04 Q2 To Start M004 05 Q3 To Start M115 06 Q4 To Start M120 07 Q5 To Start M130 08 Q6 To Start Y571 09 Q7 To Start Y6 10 Q8 To Start Y5 11 Q9 To Start Y3 12 Q10 To Start Y1 13 Q11 To Indicate ERROR 14 Q12 To Indicate WARNING 15 Q13 To Indicate RUNNING 16 Q14 17 Q15 18 Q16
- 29. SCHEMETIC DIAGRAM OF SIMULATOR
- 30. 3 PHASE MOTOR INTERFACING
- 31. SINGLE PHASE MOTOR INTERFACING
- 32. PLC O/P TO RELAY INTERFACING
- 33. SENSOR TO I/P INTERFACING
- 34. APPLICATION • Machine TD02 has two mode of programming Working mode and Service mode in working mode machine automatically sense the drive position and material status and these information is given to the PLC and according to the input condition and machine working PLC operate motors, drives and valves when in Service mode there are two mode Manual mode and Auto mode. • In Manual mode we have to independently select each and every motor, drive, sensor, valve and lamp start them and stop them after noting the information about whether it working properly or not. If not then maintenance is require for the machine. • In Auto mode machine Automatically select each and every motor ,drive,sensor,valve and lamp start them and stop them to note the information about whether it work properly or not. If maintenance is require then go to maintenance mode of machine. • We here replace microcomputer system and NOM3 module from the Control panel of the TD02 with the B&R PLC and program it to work same as microcomputer system and NOM3 module to save cost of up to 1.25 lakh. Rs.