A new generation of true color human-machine interface AI-2070C split-type paperless recorder, all Chinese touch operation, easy to operate, easy to learn. The real-time operation control in the flow chart has surpassed the general paperless recorder in function, and integrates the functions of the man-machine interface and the paperless recorder to display various types of data in full screen.
I. Overview The current production line efficiency monitoring of the factory mentioned that the management schedule has come up, requiring the production enterprise to check the [starting] [downtime] operating rate of the equipment such as: machinery, food, clothing, etc., temperature and pressure on the production line. The flow process parameters and alarm data are recorded and the problem is solved in time. However, its production line is relatively long and difficult to manage. If a problem occurs in a certain position on the production line, it will seriously affect the operation of the entire production line and the production efficiency of the production line.
At present, most of the production lines in the production of manual parts, manual counting, manual copying of temperature, pressure, flow data, easy to make mistakes, but also easy to cause data loss, is not conducive to data preservation, statistics, analysis, and waste a lot of manpower and Material resources.
In order to solve the problems of the current production line efficiency monitoring in the factory, the new generation of real-color human-machine interface AI-2070C split-type paperless recorder establishes a complete production monitoring system, using various measurement and control modules independently developed by the company. The transmission module is composed, which completely solves the problem of on-site production line management, improves the production efficiency of the production line, realizes intelligent and scientific management, improves the management level of the whole, and achieves important functions such as improving production efficiency and ensuring production quality.
A new generation of true color human-machine interface AI-2070C split-type paperless recorder, all Chinese touch operation, easy to operate, easy to learn. The real-time operation control in the flow chart has surpassed the general paperless recorder in function, and integrates the functions of the man-machine interface and the paperless recorder to display various types of data in full screen.
Second, the efficiency monitoring system set up pipeline monitoring using the upper computer (true color man-machine interface) + lower computer (AI module instrument) structure, bus connection, according to the address arrangement, each AI instrument independently running display, mutual interference, power The operation can be displayed; the RS485 communication line is connected and ready to use.
Efficiency monitoring such as: production line motor control [start], [stop] connect AI-3013D5 switch 8-channel relay output module, address set No. 33; production line motor [start-stop] count statistics: connect AI-3011D5 switch quantity 8 input dry contact.
Process measurement and control such as: production line process control includes various types of temperature, pressure, flow, frequency and other signals, including artificial intelligence PID adjustment, flow calculation, electricity measurement and other functions, can be configured as needed, any combination. The input and output specifications are extremely rich, and you can choose one-way or multi-channel display alarm, smart regulator, handheld communicator, flow totalizer or digital input and output module.
The AI-2070C split paperless recorder and measurement and control instrument can be purchased separately and can be freely expanded. Each recorder can select 2, 4, 6, 8, 12, 18, 24, 30, 36 channel type software; free editing options AI channel hardware model; writable device bit number such as: [TIC-101]; unit of measurement [°C]; parameter setting password [111].
The system performs full isolation sampling, recording and communication remote transmission of the measurement signal, and can complete multi-channel relay and digital input/output control functions. Meet the requirements of reliable real-time control and easy operation in the industrial field. Adapt to mechanical equipment "target=_blank> mechanical equipment work efficiency monitor application.
Third, the efficiency monitoring system function A new generation of true color human-machine interface AI2070C split paperless recorder monitoring factory production line machinery and equipment "target=_blank> mechanical equipment [on] [down] efficiency monitoring, statistical equipment [start] cumulative time , [on] the cumulative number of records; at the same time the factory production line machinery and equipment "target=_blank> mechanical equipment temperature, pressure, artificial intelligence PID adjustment; flow calculation, electricity measurement and other process parameters, using extrapolated 2G data electronic disk to save data The data is stored according to the principle of first-in-first-out; the data is saved for more than three years, and the function of querying by year, month, day and hour is provided, and the report data (see figure) is formed to quickly and effectively make statistics on the production efficiency of the machine. The operation mode adopts the all-Chinese culture display and provides a friendly man-machine interface, which is convenient for users to use and operate.
UAV AI series adjustment instrument is used as the measurement and control input module to realize multi-channel digital full-screen display field control equipment, which can be configured as needed and combined in any combination.
Mainly have the following functions:
1. Real-time equipment status statistics of the current work station [cumulative time], [starting times]. The temperature, pressure, flow rate and artificial intelligence PID adjustment process parameters of the production line process control are displayed.
2, real-time, historical data trend curve analysis in [real-time curve] [history curve] in the order of the channel 1, 2, 3, 4 fixed together, intuitive display of the relationship between the relevant channels. Click [Data Frame] to return to the [Single Curve] screen. Click [S] or [Range Settings] on the [Real Time Curve] and [History Curve] screens to enable single or four curves to display trend changes; set the query start time and Time span; different curve ranges enable a single query. The combination channel is switched by [Previous] and [Next].
3. Real-time query data Click [S] in the lower right corner of [Report] to display the current start time and modify the start time of the query: year/month/day/hour/minute/second; modify time span: hour/minute / sec setting; set the data query line interval [6 ~ 43200 seconds], used to quickly sample the data in the database; click the [confirm] button, the system immediately displays the data report; alarm report; the recommended time span is as short as possible, improve the data query speed.
4. Historical data centralized management mode, external CF card to save data. According to the actual needs of the customer, you can set the sampling time of the data, the storage interval and whether to save the record, whether to save the data to the CF card and other functions immediately. The dumped data is directly opened on the PC through the card reader, and the data is backed up to the computer. Software processing functions, data statistics query by year, month, day, etc.; use [Yudian paperless recorder graphics software] to read the data curve; to meet different needs.
Fourth, the efficiency monitoring data processing data stored in the electronic flash memory card, use the card reader to copy the data on the PC to the PC with the graphics software to open the data; CF card: [AL] data packet is the alarm report; [DL] data packet Is a data report; save the data source file by year/month/day/hour. The data to be saved is encrypted and must be read using dedicated UPC PC graphics software.
Encrypted Data Packets Reading Graphics Software on PC: DataLogTool 1.0 graphics software is specially developed for paperless recorders. A tool software that can be run on a computer. Its function is to record the encryption of the paperless recorder on the CF card. The centralized data management makes it easy for users to query data reports, view historical curves, and print them. In the [Start] program of the computer, there is a help file for [Yudian Paperless Recorder Graphics Software]. Click the [View Report] button to display the open record data and the alarm record file or the data that the user has queried from the CF card, and display it in the form of a report.
1. View the report: Click the [View Report] button to display the open record data and the alarm record file or the data that the user has queried from the CF card, and display it in the form of graphs and reports.
Pipeline motor working efficiency monitoring times graph: Open the graphics software to move the mouse on the graph, the column shows the number of boot.
Pipeline temperature, pressure, flow process data report graph:
2. View the curve: Click the [View Curve] button to display the data that has been queried in the report and displayed in the report mode, and displayed in the form of a curve. The curve shown above can be divided into several parts:
1 The top middle part of the graph shows the name of the record of the query;
2 is followed by the [current time] column, indicating a certain point in time at the position where the current cursor line is located;
3 For the operation of the cursor line, the user can click on the graph with the left button of the mouse, or use the left and right of the keyboard “4 immediately after the “current time†column to display the name and color of the curve the user wants. Line type and other attributes. The value in the brackets of the curve name ( ) indicates the sampled value of each curve at the position where the current cursor line is located;
5 Another part is that the X axis is displayed as the time axis, and the Y axis is displayed as the upper and lower limits of the value;
6 Double-click the graph with the left mouse button, and you can also pop up the box for the curve setting property;
3. Curve setting: Click the [Curve Setting] button to define the attribute of the curve display according to the user's needs;
1 Select the number of curves to be drawn, and you can freely choose which data you want.
2 Set the color and line type of each curve. First click with the left mouse button to select the curve displayed in the [Select Curves Displayed] list, and then select the color or line type in [Curve Properties];
3 Set the image display properties: the user can select the background color of the curve image and whether to display the XY axis grid line (the default is display);
4, text editing function: you can change the channel name of the curve and report display, title name and add notes as needed. In addition, your settings for these names and the property settings for the curve display can also be [Save] in the way of the configuration file, and perform the operations of [Import] and [Export] so that you do not have to reset these properties for the next use.
V. Case Description: Efficiency monitoring of production line motor, drying and spraying equipment
The pipeline monitoring system is mainly to realize the monitoring functions of each station in the production line, such as:
1. Pipeline motor control [Start], [Stop] Connect AI-3013D5 switch 8-channel relay output module, address is set to 33, motor [start-stop] count statistics: connect AI-3011D5 switch 8 input dry contacts,
Temperature automatic control, select instrument AI-808X3L1L1S4; replace various control output modules can control: AC contactor, solid state relay, thyristor, frequency converter, solenoid valve, regulating valve, switch output contact, etc.
2, centrifuge [start], [stop] connect AI-3013D5 switch 8-channel relay output module, the address is set to 33,
Centrifuge [on/off] count statistics: connect AI-3011D5 switch 8 input dry contacts,
Speed ​​adjustment of centrifugal atomizer: According to the viscosity of many varieties of materials, sampling frequency conversion stepless speed regulation function. Use AI-808FX3L1L1S4
3, spray granulation electromechanical "target=_blank> electromechanical hammer [open] [stop] connect AI-3013D5 switch 8-channel relay output module, the address is set to 33,
Electric hammer machine [on/off] count statistics: connect AI-3011D5 switch 8 input dry contacts,
Spray drying granulator filter set up various pressure, differential pressure detection alarm point selection instrument AI-706MJ4J4J4L1S
4, motor power "target=_blank> machine voltage, current, power measurement: current, power measurement monitoring, instrument model: AI-601ANX3L5L5S4 type AC current / voltage / power universal type measurement display alarm instrument; standard type, input voltage 0 ~500VAC, current 0~5A has one AC voltage and one AC current signal input with transformer isolation. The measurement accuracy is up to 0.2 level. The main board is isolated from strong power and supports communication, transmission and alarm functions. Supports up to four channels. The alarm function includes two upper limit and two lower limit alarms, which can be output independently or share one relay output.
7. Selection summary The AI ​​split type paperless recorder is used to monitor the mechanical equipment "target=_blank> mechanical equipment work efficiency, record the process parameters of the monitoring equipment and equipment efficiency at any time, and provide detailed data reports.
Sixth, equipment installation and commissioning:
AI-2070C split type paperless recorder is connected with the lower computer (AI module instrument) bus by the upper computer (new generation real color man-machine interface), arranged by address, each AI instrument runs independently and does not interfere with each other. Power-on can display the operation; set the address number of each meter to display the work normally. The control instruments are arranged in 1, 2, 3, and in order; the industrial real-time data is displayed on the paperless recorder in an intuitive full screen;
Production line efficiency monitoring
In the flow chart, the operator can control the motor [start] and [stop] very intuitively, and connect the AI-3013D5 switch 8-channel relay output module. The address is set to 33. The switch button in the figure can control 4 motors to start and stop; Connect AI-3011D5 switch 8 input dry contacts, address 37, display device running status, statistics [start], [stop] times [Figure 2];
The use of vivid graphic images to describe the on-site production process is the epitome of the entire industrial site. It is more than just a picture, it visually displays real-time data from industrial sites, giving operators a very intuitive remote control.
Pipeline temperature, pressure, flow regulation temperature, pressure, flow, artificial intelligence PID adjustment [Figure 5] AI display control instrument performance: the platform concept is used first, the very professional digital adjustment instrument is converted to platform design The product can achieve faster progress and higher performance/price ratio than the previous closed design products. It includes a highly versatile hardware motherboard (including I/O interface and module socket, display interface socket, A/D conversion unit and power supply unit). By installing different software and CPU, input/output modules and display interface, it can Process instrument control requirements for a variety of different functions, such as thermostats, regulators, complex loop regulators and dual loop regulators, multi-channel surveyors and flow metering instruments. Full-featured and stable performance, a variety of input and output functions can be realized by changing the internal parameters of the instrument.
Debugging of the instrument AI-808 artificial intelligence adjustment algorithm is a new algorithm that uses fuzzy rules for PID adjustment. When the error is large, the fuzzy algorithm is used to adjust to eliminate the PID saturation integral phenomenon. When the error is small, the improved PID is adopted. The algorithm adjusts and can automatically learn and memorize some features of the controlled object in the adjustment to optimize the effect. It has the characteristics of no overshoot, high precision, simple parameter determination, and good control effect on complex objects.
In the process of use, the AI ​​regulator combines PID adjustment, self-learning and fuzzy control technology to realize the self-tuning/adaptive function, and the precise adjustment without undershoot, which is far superior to the traditional PID regulator. Control equipment assembly
Instrument self-tuning method:
In the process of use, it must first be self-tuning: self-tuning is to let the thermostat perform ON/OFF (bit) control. After 2-3 oscillation cycles, the internal microprocessor of the instrument will analyze the cycle according to the oscillation generated by the position control. , amplitude and waveform to automatically calculate M5, P, T
And other control parameters.
The parameter values ​​obtained by the system under different set values ​​are not exactly the same. Before executing the auto-tuning function, the set value should be set to the most common value or the intermediate value. If it is a program type meter, please take the first paragraph. C01=Modify the setting to the maximum value used by the system, and then perform the function of starting the auto-tuning. The setting of parameters CtI (control cycle) and dF (hysteresis) also have an effect on the self-tuning process. Generally speaking, the smaller the set values ​​of these two parameters, the higher the accuracy of the theoretical self-tuning parameters. However, if the dF value is too small, the meter may cause a misalignment of the position adjustment near the given value due to the input fluctuation, which may instead set a completely wrong parameter. It is recommended that CtI = 0-2 and dF = 2.0. In addition, based on the reason for learning, the first time after the end of auto-tuning, the control effect may not be optimal, and it takes a period of time (usually the same time as auto-tuning) to get the best results. If the system is an electric furnace with good insulation performance, the set value should be set at the maximum value used by the system, and then the operation function of starting auto-tuning should be performed. The setting of parameters CtI (control cycle) and dF (hysteresis) also have an effect on the self-tuning process. Generally speaking, the smaller the set values ​​of these two parameters, the higher the accuracy of the theoretical self-tuning parameters. However, if the dF value is too small, the meter may cause a misalignment of the position adjustment near the given value due to the input fluctuation, which may instead set a completely wrong parameter. It is recommended that CtI = 0-2 and dF = 2.0. In addition, based on the reason for learning, the first time after the end of self-tuning, the control effect may not be optimal. It takes a period of time (usually the same time as the self-tuning) to get the best effect. The system can be put into the self-tuning system. run.
Seven, the conclusion:
Production line efficiency monitoring AI-2070C split paperless recorder is mainly to achieve the monitoring function of each station of the production line, complete the process of the [start] [stop] efficiency of the various lines of the production line and the process control of the production line Real-time monitoring and recording of temperature, pressure, flow and process parameter information. All data is saved in the external CD card 2G electronic disk to save data, in order to query the status of the current production line, the process parameters are clear at a glance, and the information is provided to the management personnel. The management personnel can timely understand the current status and make corresponding management measures at any time and place, so as to realize the scientific management of the entire production line, and achieve the effects of improving production efficiency and ensuring production quality.
A new generation of true color human-machine interface AI split-type paperless recorder is widely used in chemical, metallurgy, petroleum, pharmaceutical, food, electric furnace, constant temperature and humidity box, mechanical equipment "target=_blank> mechanical equipment supporting, laboratory mobile control screen Or used for the production efficiency monitoring of mechanical equipment such as packaging, injection molding machines, textile machinery and other "target=_blank> machinery. This system can also be used as an operational display in many industries such as small DCS control systems.
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