Hydraulic Press Automation Course Work

Contents

Introduction

1 Process Analysis

1.1 Process description with short

characteristics of process equipment

1.2 Description of the selected automation object,

its characteristics and features

2 Development of process automation systems

2.1 Analysis of the planned control system and selection of parameters to be automated

2.2 Selection of hardware for system construction

automation

3 Description of the accepted automation system

3.1 Automation diagram

3.2 Electrical Schematic Diagram

4 Measures to save raw materials

and fuel and energy resources

5 Occupational safety and safety measures

Safe Life

Conclusion

List of literature used

Graphic part

automation diagram

electrical circuit diagram

Introduction

The design objectives are:

acquisition of skills for self-employment,

consolidation and deepening of theoretical and practical knowledge in the discipline

"Automation of technological processes in the construction materials industry"

using them to solve specific problems using the example of "APCS for pressing facing tiles"

development of skills to conduct independent design work and mastery of design methods

Main tasks to be solved in the project

select technical means for process automation

Describe the selected tools and their characteristics

Develop and execute an automation circuit and a circuit diagram

describe the schemes developed

Development of process automation systems

2.1 Analysis of the planned control system and selection of parameters to be automated

The automated system is designed to control technological processes in hydraulic presses, rational use of energy resources, increase reliability, inform maintenance personnel about the process, increase production culture.

The automated system (AC) is designed for continuous-discrete process.

IVS is a multilevel automation system that performs the following functions:

- Collection, processing of analog and discrete signals;

- Analysis and notification of emergency situations, logging of emergency situations;

- Analysis of controlled process parameters with output of signals of deviation from technical requirements to the operator;

- Control of the main process parameters in accordance with the process regulations;

- Automatic and manual control of actuators;

- Logging of events occurring during the process;

- Real-time process control;

- Implementation of technological interlocks;

- Testing and self-diagnostics of equipment;

- Protection against software destruction and unauthorized access to information;

- Processing of pre-emergency process situations;

- Process emergency handling.

Objectives of System Creation

The purpose of creating and implementing an automated system is to achieve optimal production and economic, technological and technical parameters of process equipment operation due to the introduction of modern and advanced control technologies.

The main objective is achieved by:

- Improved accuracy of process parameters control;

- High efficiency of process control;

expansion of information and control functions of the system;

- Providing personnel with sufficient, reliable and timely information on the process progress and equipment condition for operational control;

- Increase of labor productivity of maintenance personnel;

- Reduced impact of the human factor on the production process;

- Recording of process parameters for further analysis;

- Automated monitoring of operators and maintenance personnel performance;

- Development and recording of pre-accident situations;

- Development and recording of emergency situations.

The following monitoring and control loops are provided for the created system:

Control and control of bottom punch temperature

Upper punch temperature control and control

Control and control of lower matrix temperature

Control of press powder level in the press hopper

Pressure monitoring in the hydraulic system of the press

There are also parameters for disconnecting or generating alarm messages:

No or insufficient pressure in hydraulic system

Dirty oil filter

No press powder in hopper

Description of the accepted automation system

3.1 Description of the automation functional diagram

Tile pressing press is a complex equipment. In order to carry out its functions, the following activities are envisaged:

Control and control of bottom punch temperature

Upper punch temperature control and control

Control and control of lower matrix temperature

Control of press powder level in the press hopper

Pressure monitoring in the hydraulic system of the press

Dirty oil filter

Control of cross-arm movement

Control of press carriage movement

The temperature of the lower punches is controlled and controlled as follows. From thermocouple (pos. 1-1) via thermoelectrode wires the signal is transmitted to the analog input of the controller. The received signal is compared with the specified value, which can be changed from the operator console. If there is a mismatch, a control signal appears that turns on or off the heating of the lower punches. This process is continuous, since the heats cannot be constantly turned on (the temperature will continuously increase), so they are turned off when the given temperature is reached and turned on when the minimum permissible temperature is reached (as a rule, it is 2-3 degrees below the given one).

The temperature of the upper punches is controlled and controlled as follows. From thermocouple (pos. 2-1) via thermoelectrode wires the signal is transmitted to the analog input of the controller. The received signal is compared with the specified value, which can be changed from the operator console. If there is a mismatch, a control signal appears that turns on or off the preheating of the punches.

The temperature of the lower die is controlled and controlled as follows. From thermocouple (pos. 3-1) via thermoelectrode wires the signal is transmitted to the analog input of the controller. The received signal is compared with the specified value, which can be changed from the operator console. If there is a mismatch, a control signal appears that turns on or off the heating of the bottom die.

Level sensor (pos. 101). When filling the hopper, it operates and a signal is sent to the press that allows the machine to operate. When the hopper is emptied below the sensor, the machine stops to prevent damage to the dies during operation without press powder.

Pressure sensor (pos. 111), which controls the oil pressure in the hydraulic system of the press. This sensor is a relay that operates at a certain pressure value. Thus, when the pressure drops below the critical level, our sensor operates and the machine stops.

Pressure sensor (pos. 121), which controls the oil pressure on the filter element. This sensor is a relay that operates at a certain pressure value. Thus, when the pressure increases, our sensor operates and the machine stops. This is necessary so that due to the arrival of various impurities forming the precipitate, there is no damage to the cylinder piston, which in turn will lead to the press stopping for repair.

The traverse movement is monitored so that the signal from the encoder (pos. 4-1) is supplied to the input module of the controller CQM1HCPU51. The coordinates of the movement are compared with the specified values and if there is a mismatch, the press stops.

The movement of the press carriage is monitored so that the signal from the encoder (pos. 5-1) is supplied to the input module of the controller CQM1HCPU51. The coordinates of the movement are compared with the specified values and if there is a mismatch, the press stops.

3.2 Description of circuit diagram.

In this course design, all automation devices and equipment are connected to the OMRON controller, which controls the entire process. The controller is powered by a 220 V supply via wires 43 and N.

Information on change of temperature of lower punches is transmitted via thermoelectrode wires to converter terminals 1 and 2 (pos. 1-2). The temperature change signal from the converter terminals is transmitted via wires 10 and 11 to input module AD004 of controller CQM1HCPU51. The resulting signal is compared to a predetermined value. If there is a mismatch, a control signal appears that turns on or off the preheating of the punches. The punches are switched on as follows. A control signal appears at the output, which is transmitted to the relay coil via wire 35 (pos. 1-3). At coil actuation, relay contacts are closed and punch heating is started (pos. 1-4).

Signal of change of temperature of upper punches is transmitted via thermoelectrode wires to terminals 1 and 2 of converter (pos. 2-2). The temperature change signal from the converter terminals is transmitted via wires 12 and 13 to the input module AD004 of the controller CQM1HCPU51. The resulting signal is compared to a predetermined value. If there is a mismatch, a control signal appears that turns on or off the preheating of the punches. The punches are switched on as follows. At the output, a control signal appears, which is transmitted through wire 36 to the relay coil (pos. 2-3). At coil actuation, relay contacts are closed and punch heating is started (pos. 2-4).

Information on change of lower matrix temperature is transmitted via thermoelectrode wires to converter terminals 1 and 2 (pos. 3-2). The temperature change signal from the converter terminals is transmitted via wires 14 and 15 to the input module AD004 of the controller CQM1HCPU51. The resulting signal is compared to a predetermined value. If there is a mismatch, a control signal appears that turns on or off the preheating of the punches. The punches are switched on as follows. A control signal appears at the output, which is transmitted to the relay coil via wire 37 (pos. 3-3). At coil actuation, relay contacts are closed and punch heating is started (pos. 3-4).

The traverse movement is monitored so that the signal from the encoder (pos. 4-1) is fed via wires 16 and 17 to input module AD004 of controller CQM1HCPU51. The coordinates of the movement are compared with the specified values and if there is a mismatch, the press stops.

The traverse movement is monitored so that the signal from the encoder (pos. 4-1) is supplied to the input module of the controller CQM1HCPU51. Coordinates of movement are compared with specified values and in case of mismatch there is an emergency stop of the press.

The movement of the press carriage is monitored so that the signal from the encoder (pos. 5-1) is supplied to the input module of the controller CQM1HCPU51. Coordinates of movement are compared with specified values and in case of mismatch there is an emergency stop of the press.

The control of the opening/closing of the powder bin is as follows. When the gate is opened or closed, the magnet moves inside the pneumatic cylinder, which is the actuator. When the piston takes one of its extreme positions, one of the position sensors (pos. 61, 7-1). The signal from them comes from the input module ID212 of the controller CQM1HCPU51.

Level sensor (pos. 101) the signal from which is supplied to the input module ID212 of the controller CQM1HCPU51. When filling the hopper, it operates and a signal is sent to the press that allows the machine to operate. When the hopper is emptied below the sensor, the machine stops to prevent damage to the dies during operation without press powder.

Pressure sensor (pos. 111), the signal from which is supplied to the input module ID212 of the controller CQM1HCPU51. This sensor is a relay that operates at a certain pressure value. Thus, when the pressure drops below the critical level, our sensor operates and the machine stops.

Pressure sensor (pos. 121), the signal from which is supplied to the input module ID212 of the controller CQM1HCPU51. This sensor is a relay that operates at a certain pressure value. Thus, when the pressure increases, our sensor operates and the machine stops.

The motor of the oil supply pump is switched on as follows. A control signal appears at the output, which is transmitted to the starter coil via wire 30 (pos. 141). When the coil operates, the starter contacts are closed and the pump motor is switched on (pos. 142).

Opening the gate on the powder bin. Relay power supply (pos. 131) is received when a signal appears on the output module OC222 of the controller CQM1HCPU51. The signal is transmitted for 34 to the terminal of relay 3. The relay coil is actuated and its linear contacts are closed, when contacts 1 and 5 are closed, a minus occurs (cause 5), plus (cause 6) is switched by closing contacts 2 and 6. Voltage from starter on the basis of 34.1 and 34.2 is supplied to terminals 1 and 2 of pneumatic cylinder (pos. 182). Power is supplied while there is an output signal.

Conclusion

- Studied the process of hydraulic press;

- Selected process parameters required for control, control and alarm;

- Performed automation diagram and schematic electrical diagram;

- Described the implemented diagrams;

- Developed measures to save raw materials and fuel and energy resources;

- Developed occupational safety and safety measures