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Beer filling, Gland machine PLC control system
1. Intorduction
Malt beer production process is divided into manufacturing, manufacturing wort, before fermentation, after fermentation, filtration sterilization, packaging, and so few procedures. Beer filling, Gland part of a packaging machine processes. The membrane filtration of beer after the pipeline into the rotary Jiugang, then the valve into the bottle of wine, Gland, was bottled beer. Beer filling, Gland machine's efficiency and degree of automation direct impact on the level of beer production.
China's beer industry to meet the increasing scale of production and the demand for beer modern high-speed filling machinery filling the requirements of domestic beer manufacturers are actively seeking to transform the unit or the filling of beer production equipment, making it a good use Performance, advanced technology and high production efficiency and operating a safe and secure, low maintenance costs of the modernization of beer filling machine.
2. Filling beer, Gland principle and control aircraft parts
Liquid filling machine by filling principle can be divided into atmospheric filler,filling machines and vacuum pressure on the filling machine. Beer filling,Gland-filling method used pressure is higher than the atmospheric pressure under the filling, storage of the cylinder pressure than the pressure of the bottle, beer bottle into the liquid on pressure.
Technology at home and abroad to achieve the filling line is basically: The Rotary Jiugang the rotating movement, placed in Jiugang slots on the empty bottles through the machinery will be fixed at the upper Jiugang vacuum valve to open, closed Vacuum bottles for good treatment, Bozhuan stem from operating, open the valve of the bottle filling CO2 gases, vacuum convex .Round to open the vacuum valve, the bottle will air mixed with CO2 out of gas, open the valve again, the CO2 gas bottle filling, the filling valve on the pressure valve in the bottle close to back-pressure gas pressure at the open-Jiuye Pingbi into the bottle, through pneumatic or electrical control filling valve to achieve the filling of beer.
Today's advanced international beer filling, Gland machine control system mainly by the photoelectric switch position detection part and take the bottles with, Jiugang speed part, dominated by the PLC, touch screen and other components. Filling, Gland of the mechanical structure and PLC programmable control devices, frequency stepless speed regulation, human-computer interface, and other modern means of complete automatic control technology, the combination of a mechanical and electrical integration.
3. Controlled part of the programme
Many domestic beer manufacturers are now using the filling, Gland of the control system of uneven degree of automation; button and all the manual switch technology have set up operations in a box on the panel, PLC controller for the majority of Japanese companies or OMRON Mitsubishi's early products, equipment chain of control, less protection settings, plus the beer filling the scene poor environment, humidity, such as contact with the switch contacts serious corrosion, the system's signal detection of the high failure rate, resulting in equipment control system Operation of low reliability, the normal operation of equipment, such as short-cycle phenomenon.
To the actual transformation of the Dandong Yalu River Brewery Co., Ltd. of filling, Gland machine control system as an example, the transformation of methods to clarify the control of such equipment thinking and ideas, according to the scene of the actual process conditions, to prepare the operation of the PLC Procedures. For beer filling, Gland control system of the actual situation and in accordance with the actual process conditions at the scene, re-design of the equipment of the PLC control system. This transformation of the same methods and ideas can be applied to other liquids and the transformation of filling equipment.
3.1 system hardware configuration
Japan's Mitsubishi Corporation to use the FX2N128MRPLC use the system to replace the original 2-OMRON's C60P PLC, the original system of the PLC is due to old models, and computer on-line communications need to configure special converters, the system need to increase the external I / O input points , The extension of spare parts more difficult to find. FX2N128MRPLC is an integrated 128-point I / O controller of the box, a computing speed, command rich, high-cost performance, on-line programming simple and easy extension of the advantages of the Mitsubishi FX series, features the strongest small controller .
(1) by the Mitsubishi 900 series of 970 GOT human-computer touch screen system to replace the original use of the button panel display equipment and monitor the operation of operating parameters. 970GOT HMI for the 16-color high-brightness significantly, through the convergence of connectivity and FX2N128MRPLC directly connected to the CPU, achieving rapid response. Has many maintenance features, such as the list-editing features, ladder monitoring (troubleshooting) function, the system monitoring functions to find fault and maintenance of PLC Systems.
(2) filling, Gland of the frequency converter in the transformation of no replacement, on-site detection signal means-testing is still used switch, switch for detecting long-term work in the humidity of the great occasions, the choice of capacitive proximity switches, according to PLC I / O terminal of the connection mode, select the type of close PNP switch, the control system of Figure 1.
3.2 Systems Programming
PLC controller programming focus and the core is around Jiugang the rotation speed control and Jiugang on 60 bottles of detecting the location of the displaced, broken bottles, empty bottles at the location of testing and related displacement filling Such as control valves. The bottles displacement of testing procedures, using a Mitsubishi PLC in the left command.Figure 1 control system structure diagram .
Bottles displacement of detection, using the left-PLC command, which commands the whole of one of the core control procedures, the main electrical switch detection and bottles at the bottle simultaneously detect mobile, the main motor to every week, just to the corresponding Jiugang Have a bottle of, PLC unit within the internal correspondence that 60 bottles of the unit for the M500 ~ M559, the number of units by the first letter K is set to K60, with each change in a second letter K is set to K1, M50 Reaction of the empty bottles in the short position, and detect the location of the motor speed to go on the frequency shift in the corresponding unit within the built-in "1" or "0", control valves and the corresponding mixing caps The motor stopped and opened. Continuous detection system in place after the 90 empty bottles, stop stirring caps the motor running, testing the number of bottles in accordance with the user's requirements can be arbitrary.
A bottle of detection. Rotary Jiugang through pressure to back pressure with the bottle of liquor in the process of empty bottles in the back-pressure, because the bottle itself may crack and other reasons leading to a sudden burst bottles, which need to detect the location of unexploded bottle bottle, in this bottle - The position opened purge solenoid valves, compressed air out, broken bottles at the bottle-blowing from the position in a row after the purge and several bottles of the electromagnetic valve open jet, a high-pressure spray Shuizhu, in the break Bottle position around a few bottles of spray bottles in a row.
Detection of broken bottles and bottle-detection switch simultaneously detect movement of breaking bottles, to the main motor of each week, precisely corresponding Jiugang passed a bottle of, PLC unit within the internal correspondence that 20 broken bottles at the unit for the M600 ~ M619, unit With the number of the first letter K is set to K20, with each change in a second letter K is set to K1, M52 response to the location of the broken bottles and detected the location of the motor speed to the frequency shift continue, In the corresponding unit within the built-in "1" or "0", control and the corresponding jet purge solenoid valve opened and stopped. Continuous Spray and purge solenoid valve open to listen, time stopped in accordance with technological requirements can be arbitrary.
System security is to control access to the caps simultaneously tracking, not only accurately detect the electrical switching speed detection, the broken bottles into the bottle and detection switch detection switch three conditions.
970GOT human-computer touch-screen terminals operated by the software company's Mitsubishi GT WORKS package, which is a GT Designer with the entire GOT9000 series of graphics software packages. The package is simple, prior to a personal computer simulation on the configuration and debug, after the man-machine operators to download terminals. At the same time, because the man-machine interface and a touch-screen role, will set common switch on the screen to facilitate the operation. And also to increase the number of features, such as setting alarm information.
4 After transformation control system
System at the normal operation of the machine for automatic control, in accordance with bottles into and out of the bottle for lack or slow pace set by running into the bottle stall bottles, no less than a bottle cap, automatic washing bottles burst, filling automatic back-pressure position , Covered under the system automatically lose covered a stop and safety protection, such as the coordination of action interlock. All the original button after the operation of the touch screen on.
5 Detection of the state control system monitoring
Detection switch into the bottle and break bottles detection switch bottles of pressure by testing each part of the small metal plates above the location of a photoelectric pulse output, a further PLC acquisition, as each bottle of the pressure above the small metal plates is the location of activities , In the machine running after some time, some pressure above the small bottles of iron tablets and detection switch in the location of displacement, resulting in detection switch mistaken judgement, if not for the judgement of bottles of bottles, bottle explosion Lou Jian, misuse, such as the seizure of output errors So that the PLC have mistaken action, such as a back-pressure, unexploded bottle blowing, washing, stirring cap control system malfunction, such as failure phenomenon.
Before the transformation of the daily production process, encountered this phenomenon, the operatives could only switch to the various functional or manual control buttons reach the stall so that the equipment work in the absence of monitoring state, the machine lost control function. Caused a lot of production of raw materials such as gas, water, wine waste. Only in the production of intermittent, can be fitter and maintenance electrician in accordance with the detection of small switch on the light-emitting diodes and anti-displacement by adjusting the distance only 5 ~ 8 mm detection switch installation location, and switch to fix detection of small metal plates Gap. This means of detection is very backward, after adjustment reaction to the results, timely response can not be adjusted results.
In view of this testing situation, after the transformation of the filling, Gland control system configuration, this part of a new detection and integration in human-computer touch screen, complete bottle of detection.
In human-computer touch screen interface on the page display, respectively, at customs, such as electromagnetic motor mixing valve switch state are in different colors to show, very intuitive.
Increase the system's functions is to ensure the irrigation of the machine-Gland normal operation of automated control system specifically designed to.
6 Concluding remarks
After the transformation of the control system will greatly simplify the complicated mechanical structure, the running and control of inspection, the degree of automation systems meet the design requirements, greatly reducing the operational strength of the labor so that the shrub-like beer output than in the past Raising more than 30 percent, greatly reduce the failure rate. Embodies the modern equipment of automatic control technology. In the digestion and absorption of today's industrial control on the basis of advanced technology innovation, development of domestic technology from the most advanced filling control system.
啤酒灌裝、壓蓋機(jī)PLC控制系統(tǒng)
1. 引言
啤酒生產(chǎn)過程分為麥芽制造、麥芽汁制造、前發(fā)酵、后發(fā)酵、過濾滅菌、包裝等幾道工序。啤酒灌裝、壓蓋機(jī)部分屬于包裝工序。啤酒經(jīng)膜過濾后由管路送入回轉(zhuǎn)酒缸，再經(jīng)酒閥進(jìn)入瓶子中，壓蓋后獲得瓶裝啤酒。啤酒灌裝、壓蓋機(jī)的工作效率和自動化程度的高低直接影響啤酒的日產(chǎn)量。
為了滿足我國啤酒行業(yè)日益擴(kuò)大生產(chǎn)規(guī)模的需求和啤酒現(xiàn)代化灌裝機(jī)械高速灌裝的要求，國內(nèi)各啤酒生產(chǎn)廠家都在積極尋求或改造本單位的啤酒灌裝生產(chǎn)設(shè)備，使其成為具有良好的使用性能，先進(jìn)的技術(shù)水平及高生產(chǎn)效率、運行穩(wěn)妥可靠、維護(hù)成本低的啤酒現(xiàn)代化灌裝機(jī)。
2. 啤酒灌裝、壓蓋機(jī)工作原理和控制部分構(gòu)成
液體灌裝機(jī)按灌裝原理可分為常壓灌裝機(jī)、壓力灌裝機(jī)和真空灌裝機(jī)。啤酒灌裝、壓蓋機(jī)采用壓力灌裝方法，是在高于大氣壓力下進(jìn)行灌裝，貯液缸內(nèi)的壓力高于瓶中的壓力，啤酒液體靠壓差流入瓶內(nèi)。
目前國內(nèi)外實現(xiàn)灌裝工藝路線基本上是：利用回轉(zhuǎn)酒缸產(chǎn)生的旋轉(zhuǎn)運動，使安放在酒缸槽位上的空瓶通過機(jī)械機(jī)構(gòu)將固定在酒缸上部的欲抽真空閥打開，對已封好的瓶子進(jìn)行抽真空處理，撥轉(zhuǎn)外操作閥桿，打開氣閥，對瓶內(nèi)充填CO2氣體，抽真空凸輪繼續(xù)打開真空閥，將瓶內(nèi)空氣與CO2混合氣體抽出，氣閥再次打開，對瓶內(nèi)充填CO2氣體，灌裝閥內(nèi)的液閥在瓶內(nèi)壓力接近背壓氣體壓力時打開，酒液順瓶壁注入瓶內(nèi)，通過氣動或電動控制灌裝閥實現(xiàn)啤酒的灌裝。
當(dāng)今國際先進(jìn)的啤酒灌裝、壓蓋機(jī)的控制系統(tǒng)主要由光電開關(guān)位置檢測部分、走瓶帶、酒缸轉(zhuǎn)速的變頻調(diào)速部分、主控由可編程控制器、觸摸屏等組成。灌裝、壓蓋機(jī)的機(jī)械結(jié)構(gòu)裝置與PLC可編程控制、變頻無級調(diào)速、人機(jī)界面等現(xiàn)代自動控制技術(shù)手段完整的結(jié)合，形成機(jī)電一體化。
3. 控制部分改造方案
國內(nèi)很多啤酒廠家現(xiàn)使用的灌裝、壓蓋機(jī)的控制系統(tǒng)的自動化程度參差不齊；所有手動按鈕和工藝開關(guān)都設(shè)置在一個操作箱的面板上，PLC控制器大都為日本OMRON公司或三菱公司的早期產(chǎn)品，設(shè)備連鎖控制、保護(hù)設(shè)置少，加之啤酒灌裝的現(xiàn)場環(huán)境惡劣，潮濕度大，使開關(guān)等接觸觸點銹蝕嚴(yán)重，系統(tǒng)的信號檢測部分故障率較高，造成設(shè)備控制系統(tǒng)運行的可靠性低，設(shè)備正常運行周期短等現(xiàn)象。
以實際改造的丹東鴨綠江啤酒有限公司的灌裝、壓蓋機(jī)的控制系統(tǒng)為例，介紹改造方法，闡明改造這類設(shè)備的控制思想和思路；根據(jù)現(xiàn)場的實際工藝條件，重新編寫了PLC的運行程序。針對啤酒灌裝、壓蓋機(jī)控制系統(tǒng)的實際狀況，并根據(jù)現(xiàn)場的實際工藝條件，重新設(shè)計了設(shè)備的PLC控制系統(tǒng)。這種改造方法和思路同樣可以應(yīng)用與其他液體介質(zhì)灌裝設(shè)備的改造。
3.1 系統(tǒng)硬件配置
使用日本三菱公司的FX2N128MRPLC替換原系統(tǒng)使用的2臺OMRON公司的C60P PLC，原系統(tǒng)的PLC由于是老型號產(chǎn)品，和計算機(jī)聯(lián)機(jī)需要配置特殊的通訊轉(zhuǎn)換器，系統(tǒng)需要增加外部I/O輸入點時，擴(kuò)展模塊備件較難尋。FX2N128MRPLC是集成128點I/O的箱體式控制器，具有運算速度快，指令豐富、性能價格比高、聯(lián)機(jī)編程簡單、擴(kuò)展方便等優(yōu)點，是三菱FX系列中功能最強(qiáng)的小型控制器。
(1) 采用三菱公司的900系列的970GOT人機(jī)觸摸屏替換原系統(tǒng)使用的面板按鈕并監(jiān)控顯示設(shè)備的運行工作參數(shù)。970GOT HMI為高亮度的16色顯，通過匯流連接和FX2N128MRPLC的CPU直接連接，實現(xiàn)快速回應(yīng)。具有許多維護(hù)功能，如列表式編輯功能、梯形圖監(jiān)控(故障查找)功能、系統(tǒng)監(jiān)控功能等用來查找故障和維護(hù)PLC系統(tǒng)。
(2) 灌裝、壓蓋機(jī)的變頻器在改造中沒有更換，現(xiàn)場檢測信號的手段仍然采用開關(guān)式檢測，因檢測開關(guān)長期工作在濕度很大的場合，因此選擇電容式的接近開關(guān)，根據(jù)PLC I/O端子的接線方式，選擇PNP型的接近開關(guān)。
3.2. 系統(tǒng)程序設(shè)計
PLC控制器的程序設(shè)計重點和核心是圍繞著酒缸的旋轉(zhuǎn)速度控制和酒缸上60個瓶位相關(guān)位置的檢測移位、破瓶、空瓶瓶位相關(guān)位置的檢測移位和相關(guān)灌裝閥等的控制。其中的瓶位移位檢測程序中，采用了三菱PLC位左移指令。
瓶位移位檢測，采用PLC位左移指令，這條指令是整個子控制程序的核心之一，主電機(jī)和瓶位檢測開關(guān)同步檢測移動的酒瓶，主電機(jī)每轉(zhuǎn)一周，正好對應(yīng)酒缸轉(zhuǎn)過一個瓶位，PLC內(nèi)部單元內(nèi)對應(yīng)這60個瓶位的單元為M500~M559，單元個數(shù)用第一個字母K設(shè)置為K60，每次變化一位用第二個字母K設(shè)置為K1，M50反應(yīng)了瓶位的空、缺位置，并將檢測到的這個位置以電機(jī)轉(zhuǎn)速的頻率移位下去，在內(nèi)部相應(yīng)的 單元內(nèi)置"1"或"0"，控制相應(yīng)的閥門和攪拌瓶蓋的電機(jī)的開與停。系統(tǒng)在連續(xù)檢測90個空瓶位后,停止攪拌瓶蓋的電機(jī)的運行,檢測瓶位的個數(shù)可以根據(jù)用戶的要求任意設(shè)定。
出瓶位檢測?；剞D(zhuǎn)酒缸通過壓力往瓶內(nèi)背壓裝酒的過程中，空瓶在背壓后,可能由于瓶子本身裂紋等原因?qū)е峦蝗槐?這就需要檢測出爆瓶瓶子的位置,在這個瓶位的位置進(jìn)行打開吹掃電磁閥,噴出壓縮空氣,將瓶位上的碎瓶片吹離位置,在連續(xù)吹掃幾個瓶位后,在打開噴射電磁閥,噴射出高壓水注,在對破瓶位置周圍瓶位連續(xù)噴射幾個瓶位。
破瓶檢測和瓶位檢測開關(guān)同步檢測移動的破瓶，主電機(jī)每轉(zhuǎn)一周，正好對應(yīng)酒缸轉(zhuǎn)過一個瓶位，PLC內(nèi)部單元內(nèi)對應(yīng)這20個破瓶位的單元為M600~M619，單元個數(shù)用第一個字母K設(shè)置為K20，每次變化一位用第二個字母K設(shè)置為K1，M52反應(yīng)了破瓶的位置，并將檢測到的這個位置以電機(jī)轉(zhuǎn)速的頻率移位下去，在內(nèi)部相應(yīng)的 單元內(nèi)置"1"或"0"，控制相應(yīng)的噴射和吹掃電磁閥開與停。連續(xù)噴射和吹掃電磁閥的開聽、停時間可以根據(jù)工藝要求任意設(shè)定。
系統(tǒng)自動化運行可靠的保障就是控制進(jìn)出瓶蓋的同步跟蹤，既準(zhǔn)確檢測電機(jī)轉(zhuǎn)速檢測開關(guān)、破瓶檢測開關(guān)和進(jìn)瓶檢測開關(guān)三個條件。
970GOT人機(jī)觸摸屏操作終端機(jī)的軟件采用三菱公司的GT WORKS軟件包，其中GT Designer是一個用與整個GOT9000系列的繪圖套裝軟件。該軟件包操作簡單，事先可在個人計算機(jī)上組態(tài)并仿真調(diào)試，完畢后下載至人機(jī)操作終端機(jī)。同時，因為人機(jī)界面又具有觸摸屏的作用，將常用的開關(guān)設(shè)在顯示屏上，方便操作。還可并以增加一些功能，如設(shè)置報警信息等。
4．改造后控制系統(tǒng)功能
系統(tǒng)正常運行時，機(jī)器為自動控制，根據(jù)進(jìn)出瓶帶上瓶的滿缺，按設(shè)定速度或慢速運行，進(jìn)瓶檔瓶，無瓶不下蓋，爆瓶自動沖洗，灌裝位置自動背壓，下蓋輸蓋系統(tǒng)的自動開停和安全保護(hù)等動作的協(xié)調(diào)聯(lián)鎖。原來所有按鈕的操作改造后都在觸摸屏上進(jìn)行。
5．控制系統(tǒng)檢測狀態(tài)的監(jiān)控功能
進(jìn)瓶檢測開關(guān)和破瓶檢測開關(guān)通過檢測每個壓瓶部分上面的小鐵片的位置，產(chǎn)生光電脈沖輸出，再有PLC采集，由于每個壓瓶部分上面的小鐵片的位置是活動的，在機(jī)器運行一段時間后，壓瓶部分上面的小鐵片和檢測開關(guān)的位置發(fā)生位移，造成檢測開關(guān)誤判斷，如沒瓶判斷為有瓶，爆瓶漏檢、誤檢等造成輸出失誤，使PLC產(chǎn)生誤動作，造成如背壓、爆瓶吹、洗、瓶蓋攪拌系統(tǒng)控制失靈等故障現(xiàn)象。
在改造前的日常生產(chǎn)過程中，碰到這種現(xiàn)象時，操作工只能將各個功能開關(guān)或按扭打到手動控制檔位，使機(jī)器設(shè)備工作在無監(jiān)控狀態(tài)下，機(jī)器失去自動控制功能。造成了很大的生產(chǎn)原料如氣、水、酒的浪費。只能在生產(chǎn)的間歇，才能由維修鉗工和電工根據(jù)檢測開關(guān)上的小發(fā)光二極管的亮和滅通過調(diào)整位移距離只有5~8mm的檢測開關(guān)的安裝位置，來修正檢測開關(guān)和小鐵片的間隙。這種檢測手段非常落后，調(diào)整后的效果反應(yīng)致后，不能及時反應(yīng)調(diào)整結(jié)果。
針對這種檢測狀況，結(jié)合改造后的灌裝、壓蓋機(jī)控制系統(tǒng)的配置，新增了這部分檢測功能，并集成在人機(jī)觸摸屏中，完成瓶位檢測。
在人機(jī)觸摸屏的界面分頁顯示屏上，可以分別時關(guān)、攪拌電機(jī)等電磁閥的開關(guān)狀態(tài)都以不同顏色來顯示，非常直觀。
增加這套系統(tǒng)功能的是為保證灌狀壓蓋機(jī)的自動化控制系統(tǒng)正常運行而專門設(shè)計的。
6．結(jié)束語
改造后的控制系統(tǒng)大大地簡化了復(fù)雜的機(jī)械結(jié)構(gòu)，經(jīng)現(xiàn)場運行情況和控制效果檢驗，系統(tǒng)的自動化程度達(dá)到了設(shè)計要求，大大減少了操作人員的勞動強(qiáng)度，使啤酒灌狀的日產(chǎn)量比過去提高30%以上，故障率大大減低。體現(xiàn)了現(xiàn)代設(shè)備的自動控制技術(shù)。是在消化、吸收當(dāng)今工業(yè)控制的先進(jìn)技術(shù)的基礎(chǔ)上加以創(chuàng)新、研制而成的目前國內(nèi)技術(shù)最先進(jìn)的灌裝控制系統(tǒng)。