He Shunhua, Deputy Director Of Shaoyang Textile Machinery Setting Machine Research Institute: Digitalization Technology To Improve Control Level Of Setting Machine

He Shunhua,

Deputy director of Research Institute of setting machine, limited, senior electrical engineer.

Engaged in electrical design for nearly 18 years, with nearly 20 years of experience in electronic circuit design and MCU development, good at PLC, touch-screen programming and machine anti-interference and other difficult problems. It is the electrical chair design, program formulation and programming editor of M5469 and M5471, the leading products of Shaoyang textile machinery.

Nowadays, digital technology is increasingly applied to the field of electrical automatic control.

The application of electrical control is very popular, and gradually integrates electric traction, sensor technology and digital technology into one.

The role of digital technology in the electrical control of the shaping machine is mainly embodied in 3 aspects.

First, PLC and touch screen are the basis of digitalization of electrical control. The application of this equipment has completely changed the traditional electric control, and reduced the intermediate control circuit and wiring, reduced the circuit, reduced the failure rate and improved the reliability. Many complicated calculations and controls have been easily realized, greatly improving the automation level of the machine and reducing the labor intensity of the operator.

Fault instructions and historical records can help maintenance personnel quickly find and troubleshoot.

The operation maintenance cycle table reminds the maintenance personnel to maintain the machine parts in time, replace the vulnerable parts, prolong the life of the machine, and reduce the occurrence of failures.

The two is the improvement of technology and production management of the enterprise LAN. The process parameters of the shaping machine have been revised to the factory control center through the revision of many actual processing processes. After the analysis and optimization of big data, the best process with the highest efficiency, the best quality and the lowest energy consumption can be archived. At the same time, only the relevant managers can see the process and improve the confidentiality of the process.

Three is to achieve remote monitoring, troubleshooting, maintenance tips and technology upgrades. Cloud technology and intelligent gateway to achieve remote communication with the machine, real-time data acquisition and storage, through mobile phone APP or computer, all aspects of personnel at any time, anywhere, the machine running state is clear.

When the system program needs to be upgraded or modified, it can be agreed with users that time downtime can be downloaded remotely, which overcomes the shortcomings of poor communication or long time consuming of traditional after-sales service, and greatly saves time and maintenance costs.

Multiple units operate cooperatively to achieve overall control.

The digital control system includes two parts: control system hardware and PLC program control.

The electrical control system of the new setter includes PLC, touch-screen, frequency converter (servo), intelligent instrument, sensor, monitoring equipment, host computer, Internet control station and mobile phone APP. It belongs to a more comprehensive control system.

In the whole control system, PLC is the main body of the field control and the foundation of the system.

Shaoyang textile machinery chooses SIEMENS S7-1500C series PLC as the core organization of its control. Compared with similar products, it has the advantages of powerful hardware and software, and high anti-interference ability.

The touch screen system uses 3 touch screens in the front, middle and rear, and connects to the PN port of PLC through the switch.

The front screen mainly controls cloth insertion, alignment tension, rolling force tension and liquid level, drying tension, central screen as main screen, controls the whole shaping machine, and the rear screen controls cloth, cloth dropping and production statistics, so that each station operates smoothly.

The main drive frequency converter (servo) communicates with PLC.

The main drive system is the speed synchronization control system in the setting machine.

The continuous upgrading of the system requires reliable control, fast and accurate pmission of control parameters, ensuring stable, synchronous and constant tension operation and satisfying the consistency of finished fabric density.

The system adopts high-speed and reliable PN communication.

PLC communicate with fan inverter and intelligent instrument, pmit setting value, read the actual value, the system uses frequency converter, intelligent instrument standard Modbus-RTU protocol communication, so as to reduce the cost.

Remote communication, the PN port of S7-1500C series PLC can also be configured as Modbus-tcp protocol at the same time, except for Profinet protocol communication, to facilitate the establishment of factory LAN by many companies.

The user factory is composed of local area network for ERP management.

PLC is connected by intelligent gateway to cloud, communicating with remote engineer station and mobile phone.

PLC program control, S7-1500C series PLC TIA Portal programming, there are 5 programming languages, reduce program storage space, shorten the execution time of the program.

The system time setting can set the PLC internal time according to the actual time, so that the display time of the touch screen coincide with the actual time.

The main drive control includes selection of main drive system, starting and stopping control, fault alarm processing, calculation and pmission speed, over feeding rate, tension and other signals.

In case of failure, the PLC program must immediately stop the operation of the main pmission system and related parts, and notify the relevant personnel to deal with it.

The main drive system of the shaping machine is based on the main chain strip, and the units of the upper feed, the lower feeding, the left and right brushes, the cloth discharging and the falling cloth are combined in a certain speed relationship to form a hard synchronous system running in a dynamic way.

The fabric length and auxiliary pmission control are used to measure the output of the sensor after counting and calculating the length or weight.

Control the operation, stop and failure alarm of AC auxiliary pmission part.

The width control of door width can be adjusted to different widths according to the different fabric types, so as to meet the processing requirements.

When the gate limit or the angle limit is reached, the PLC stops the relevant parts and sends out the alarm to protect the safety of the guideway system.

Fan inverter control, control fan inverter selection, start and stop, PLC will run the speed of each unit, acceleration and deceleration time to the corresponding converter, read the current, fault and other parameters of each inverter.

The intelligent instrument controls, sends the setting value to the intelligent instrument in the way of communication, reads the actual value, and the fan and intelligent instrument have special communication module, which can greatly reduce the difficulty and workload of programming.

The sending and receiving buffer of PLC communicates with the host computer or remote engineer station.

Communication with upper computer realizes ERP management, on-site monitoring, uploading, downloading, optimizing process recipe, and realizing multiple machine group control.

Overall, the electrical control of the shaping machine is no longer simply able to meet the requirements of processing and production, but will be highly automated, intelligent, group controlled and remote.

Using the Internet to connect the manufacturer with the machine used by the manufacturer, through the alarm data and video analysis, realize remote diagnosis and program upgrading, change the traditional after-sales service mode, expand the scope of service, improve the service quality, help users improve the level of machine usage and maintenance, and will become the development direction of the electrical control of the shaping machine.