EP Reconstruction Example of Jiangxi Wannianqing Cement Bulk DCS Project
发布日期：2020-07-25 浏览次数：647
Bulk DCS project, bulk centralized control, high efficiency
1．Project Introduction
Jiangxi Wannianqing Cement Co.,Ltd. Wants to solve the common problems of high labor intensity, high labor costs, extensive management of the bulk section, serious dust pollution and resource waste, low loading accuracy, frequent production safety accidents and excessive reliance on experience, so we design bulk centralized control system based on WINCC and S7-300PLC control platform for them. After the system start running, it achieve the goal of centralized loading of cement in bulk, and it interacts whit the sales system to realize the effective integration of information and industrialization of cement production enterprises.
2.Design Program
The electrical control system uses Siemens software WINCC to realize monitoring, uses 2 Siemens S7-300PLC as the master station, and uses 4 computers to manage hardware. The metering system is our company’s Coriolis metering system, and every system has a Siemens S7-1200PLC as salve station. The design is modular and every salve station is linked with the master station by Ethernet, so the system is safe and reliable.
Coriolis metering system operate safely and stably with high precision so that it provides guarantee for the good operation of the entire system. In order to improve communication speed and ensure the reliable operation of the equipment, the system establishes an Ethernet communication structure, and it uses optical fiber for Long-distance transmission while shielded network cable for Short-distance transmission.
System composition structure diagram
3.System Composition
As a centralized control system for cement, the system consists of sales data collection control, automatic loading and metering，data search and precision calculation.
3.1 Sales Data Collection Control
The customer holds the IC card to each bulk point to swipe the card for verification. After the swiping system completes information collection and comparison, it outputs a digital signal to the WINCC system. The WINCC system activates the “Start Loading” button after receiving the signal. Then, the customer can start loading.
3.2 Automatic Loading and Metering
After completing the positioning of the bulk machine through video monitoring and clicking the “Start Loading” button，WINCC will send the start command to the Coriolis bulk metering system 1200PLC slave station through 300PLC. After receiving the start command, the slave station judges the loading conditions. When the conditions are met, the system starts the dust collector, flow aid fan, and switch valve in turn, and performs PID control according to the set flow and feedback flow value, and adjusts the flow control valve, so we can achieve safe, efficient and intelligent loading.
3.3 Data Search and Precision Calculation
In order to display the information of the vehicle and the accuracy of the Coriolis metering system intuitively, This system registers the powerful and flexible MsFlexGrid report to the WINCC interface， and complete the data display function by designing the stored procedure in the database. Besides, the report has functions such as compound retrieval, export and printing.
The main fields of the loading data report are shown in Table 1, and the accuracy calculation is shown in Figure 5.
Table 1. One-time loading information table
|
No |
Field name |
Field attributes |
No |
Field name |
Field attributes |
|
1 |
shipment number |
nvarchar(10) |
9 |
Metering accuracy |
numeric(8，2) |
|
2 |
Gross weight |
numeric(18，2) |
10 |
Swipe time |
datetime |
|
3 |
Car weight |
numeric(18，2) |
11 |
First weigh time |
datetime |
|
4 |
Car number |
nvarchar(50) |
12 |
Second weigh time |
datetime |
|
5 |
Load weight |
numeric(18，2) |
13 |
Loading start time |
Datetime |
|
6 |
Set weight |
numeric(18，2) |
14 |
Loading end time |
Datetime |
|
7 |
Loaded weight |
numeric(18，2) |
15 |
Cement remaining amount |
nvarchar |
|
8 |
Limited weight |
numeric(18，2) |
16 |
Loading times |
Int |
Cement Bulk Loading Report
4.Summary
Jiangxi Wannianqing DCS system is based on database structure design to realize data interaction between WINCC monitoring software and sales system. The system realizes automatic identification, verification and quantitative loading of vehicles through WINCC VBS script and SQL. It can also realize alarm processing, storage, data collection and trend processing through WINCC real-time database. The system can also integrate and manage complex report generation, export, printing, and generation of metering accuracy of weighing scales, closely integrates the process, integrates control functions, management functions and data storage functions, and realizes the management of production sites, workshops, and equipment on a regular basis. The control and management of stage information such as maintenance and management decision-making can well solve the problems of the current production line data and ERP information management system data flow in the cement enterprise's bulk loading, information feedback lag in the cement enterprise's bulk loading.。This system not only improves the automation level of enterprise management, but also improves loading efficiency, reduces labor costs, and has significant economic benefits. At the same time, it can reduce the secondary pollution of cement bulk, reduce safety accidents, improve the working environment of bulk positions, and have obvious social benefits.
Bulk DCS project, bulk centralized control, high efficiency
1．Project Introduction
Jiangxi Wannianqing Cement Co.,Ltd. Wants to solve the common problems of high labor intensity, high labor costs, extensive management of the bulk section, serious dust pollution and resource waste, low loading accuracy, frequent production safety accidents and excessive reliance on experience, so we design bulk centralized control system based on WINCC and S7-300PLC control platform for them. After the system start running, it achieve the goal of centralized loading of cement in bulk, and it interacts whit the sales system to realize the effective integration of information and industrialization of cement production enterprises.
2.Design Program
The electrical control system uses Siemens software WINCC to realize monitoring, uses 2 Siemens S7-300PLC as the master station, and uses 4 computers to manage hardware. The metering system is our company’s Coriolis metering system, and every system has a Siemens S7-1200PLC as salve station. The design is modular and every salve station is linked with the master station by Ethernet, so the system is safe and reliable.
Coriolis metering system operate safely and stably with high precision so that it provides guarantee for the good operation of the entire system. In order to improve communication speed and ensure the reliable operation of the equipment, the system establishes an Ethernet communication structure, and it uses optical fiber for Long-distance transmission while shielded network cable for Short-distance transmission.
System composition structure diagram
3.System Composition
As a centralized control system for cement, the system consists of sales data collection control, automatic loading and metering，data search and precision calculation.
3.1 Sales Data Collection Control
The customer holds the IC card to each bulk point to swipe the card for verification. After the swiping system completes information collection and comparison, it outputs a digital signal to the WINCC system. The WINCC system activates the “Start Loading” button after receiving the signal. Then, the customer can start loading.
3.2 Automatic Loading and Metering
After completing the positioning of the bulk machine through video monitoring and clicking the “Start Loading” button，WINCC will send the start command to the Coriolis bulk metering system 1200PLC slave station through 300PLC. After receiving the start command, the slave station judges the loading conditions. When the conditions are met, the system starts the dust collector, flow aid fan, and switch valve in turn, and performs PID control according to the set flow and feedback flow value, and adjusts the flow control valve, so we can achieve safe, efficient and intelligent loading.
3.3 Data Search and Precision Calculation
In order to display the information of the vehicle and the accuracy of the Coriolis metering system intuitively, This system registers the powerful and flexible MsFlexGrid report to the WINCC interface， and complete the data display function by designing the stored procedure in the database. Besides, the report has functions such as compound retrieval, export and printing.
The main fields of the loading data report are shown in Table 1, and the accuracy calculation is shown in Figure 5.
Table 1. One-time loading information table
|
No |
Field name |
Field attributes |
No |
Field name |
Field attributes |
|
1 |
shipment number |
nvarchar(10) |
9 |
Metering accuracy |
numeric(8，2) |
|
2 |
Gross weight |
numeric(18，2) |
10 |
Swipe time |
datetime |
|
3 |
Car weight |
numeric(18，2) |
11 |
First weigh time |
datetime |
|
4 |
Car number |
nvarchar(50) |
12 |
Second weigh time |
datetime |
|
5 |
Load weight |
numeric(18，2) |
13 |
Loading start time |
Datetime |
|
6 |
Set weight |
numeric(18，2) |
14 |
Loading end time |
Datetime |
|
7 |
Loaded weight |
numeric(18，2) |
15 |
Cement remaining amount |
nvarchar |
|
8 |
Limited weight |
numeric(18，2) |
16 |
Loading times |
Int |
Cement Bulk Loading Report
4.Summary
Jiangxi Wannianqing DCS system is based on database structure design to realize data interaction between WINCC monitoring software and sales system. The system realizes automatic identification, verification and quantitative loading of vehicles through WINCC VBS script and SQL. It can also realize alarm processing, storage, data collection and trend processing through WINCC real-time database. The system can also integrate and manage complex report generation, export, printing, and generation of metering accuracy of weighing scales, closely integrates the process, integrates control functions, management functions and data storage functions, and realizes the management of production sites, workshops, and equipment on a regular basis. The control and management of stage information such as maintenance and management decision-making can well solve the problems of the current production line data and ERP information management system data flow in the cement enterprise's bulk loading, information feedback lag in the cement enterprise's bulk loading.。This system not only improves the automation level of enterprise management, but also improves loading efficiency, reduces labor costs, and has significant economic benefits. At the same time, it can reduce the secondary pollution of cement bulk, reduce safety accidents, improve the working environment of bulk positions, and have obvious social benefits.
