Application of Emerson EC10 Series PLC in Block Molding Machine

1. Introduction <br> due to the rapid development of the construction industry, the demand for components of various types of brick growing. The use of clay as a raw material for bricks in the construction industry has been declining, and the resilience of the land has been very weak. The former bricks have a huge consumption of land for support; and the solid red bricks have a single product type and are difficult to meet the application requirements for various occasions.
The block forming machine can be processed into various new wall materials by industrial waste such as sand, stone, fly ash, coal slag, coal gangue, tailing slag, ceramic granules, and expanded perlite. The bricks and hollow blocks produced do not need to be sintered, saving the country's land, coal, no pollution, can increase the project speed, reduce the weight of the building, high hollow rate, sound insulation and warm, cool in winter and cool in summer, anti-weathering, original source rich, quality Good and simple production process, less effective investment, wide adaptability, broad prospects and other advantages.
The brick machine equipment has been used in a large number of electrical automation equipment. Many of the equipment have evolved from the original manual production to fully automatic production. This not only increases the technical content of the equipment, but also improves the efficiency of automated production.

Second, technology introduction

The process of the block forming machine mainly consists of four parts:
1), hydraulic system:
The main function of the hydraulic system is to control the die head of the mold and the lifting and lowering of the mold box. The use of a hydraulic system can effectively and smoothly pressurize and prevent the device from having too much impact.
2) Host:
The whole frame of the main machine is welded, and the molds are manufactured by the line cutting process, which ensures the smooth and burr-free brick blocks, and the size is accurate. For the vibration motor, some customers in the industry use ordinary motors, and some customers use frequency conversion. The device is equipped with a motor, which effectively improves the motor burnout caused by frequent start-stop. Improve the reliability of the system.
3), out of the brick conveyor belt:
The main function of the brick is to send the finished brick away from the block machine. In the brick-out part there is a grey-sweeping motor. Its main function is to clean the waste on the finished bricks. When the bricks are dry, there will be no sticky surface of the waste and keep the bricks clean.
4), according to the different needs of customers, the mold can be used with a variety of molds, use different molds can produce different requirements of the block-shaped brick, suitable for various occasions.

Third, the technical program

3.1, scheme diagram

a) The technical solution adopts HMI+PLC+MDI.
b) The current point of the block forming machine PLC is controlled at 60 points. The Emerson EC10 Series 60-point master module does not require an expansion module, which just meets customer needs.
c) Inverter The customer selects a brand of general-purpose inverter. The main use of speed control.
d) HMI This customer chooses the products of Taiwan Wellens.
e), touch screen and PLC to connect, PLC control inverter frequency change and frequency settings, PLC and inverter communication using standard MODBUS protocol. The inverter controls the frequency of production motor operation to achieve the adjustment of production efficiency.

3.2. Programming This programming uses the Sequential Function Chart (Sequential Function Chart), which uses the process division of the sequential function chart and the conversion function between the steps. The program segments can be modularly and freely combined.
Due to the intuitive and procedural features of sequential function diagram programming, each step after the decomposition and each conversion condition is a relatively simple program process, and is widely used in the field of sequential control.

After understanding the process can be divided into the following sections:

Rough material truck

Mixing

Vibration plus mixing

Material retreat

Rough material truck retreat

Dosing

Indenter

forming

Damping

Lifting frame

Indenter head, feeding plate

Frame

Pre-shock

Vibration and vibration

Pressure

Damping

This machine is divided into two working methods: manual, automatic. Select the manual mode before starting the machine. The manual buttons are all one-button start/stop buttons. Press it once to start, and then click again to stop or place the switch to stop. In the manual screen of the man-machine interface, there is a “un-interlocked” touch key. When it is turned on, it is gray. At this time, the interlocking control is cancelled. At this time, each button is a jog mode, which facilitates the debugging of the machine and the limit switches are adjusted. Always close this key to restore interlocking constraints.
This is very important to protect the safety of the machine. When it is closed, the key is white. After starting the oil pump, manually test the indenter, frame,
After the feeding car, delivery plate, finished product and conveying operation are all normal, set the production module, the number of fabrics, the advance and retreat fabric time, place the manual/automatic switch in the automatic position, press the automatic start or touch screen start button, press the molding machine Preset the program to go on until you reach the production module or press Stop to end.

3.3, PLC communication protocol setting
EC10 series PLC main module provides two serial asynchronous communication ports, which are PORT0 and PORT1 respectively. Communication port features are shown in the table.
Table 5-1 EC10 series main module communication port features

Socket type

Signal level

Way of working

Provide agreement

use

Supported baud rate (bps)

PORT0

Mini DIN8

RS232

Full duplex

Programming port protocol

User programming, debugging, monitoring, etc.

9600 and 19200

MODBUS slave

Can work with HMI; also can be used as a slave device

38400, 19200, 9600, 4800, 2400, 1200

Free agreement

User-definable protocol

38400, 19200, 9600, 4800, 2400, 1200

ECBUS Note 1

Data exchange between some components and other PLCs in the network

115200, 57600, 38400, 19200, 9600, 4800, 2400, 1200

PORT1

EK500V

RS232, RS485 available

RS232 full duplex, RS485 half duplex

MODBUS
Main site

Can be networked as a master station to control other devices

38400, 19200, 9600, 4800, 2400, 1200

MODBUS
Slaves

Can be networked as a slave device; can work with HMI

38400, 19200, 9600, 4800, 2400, 1200

Free agreement

User-definable protocol

38400, 19200, 9600, 4800, 2400, 1200

ECBUS protocol

Data exchange between some components and other PLCs in the network

115200, 57600, 38400, 19200, 9600, 4800, 2400, 1200

3.4. HMI Communication Settings
The WINVIEW port needs to set the format of the communication port. The setting interface is as follows

The touch screen is widely used in the industry because it can display the running information of the current device in real time, vividly and vividly.

A), touch screen and PLC connection through the RS232 port, PLC type selection EMERSON PLC EC20 [PDS V2.50].
B), touch screen as the main station PLC as a slave station, the use of MODBUS master-slave protocol for communication, PLC slave station address selection is 2, touch screen master station address is set to 1.
C). The communication serial port of touch screen and PLC is set to baud rate: 9600 Parity check: Even parity data bit: 8 Stop bit: 1

The block machine screen is as follows:

The manual, automatic status, flow pressure, and delay time of the block building machine can be set on the touch screen, and the current signal status can also be displayed.
These windows all vividly reflect the current operation information of the equipment. Through the application of the touch screen, we can realize the real-time monitoring of the system and incorporate it into the middle of the equipment management system monitoring system in the middle of the next level of application, so as to further enhance the equipment optimization.

3.5, drive communication protocol setting

Inverter adopts a brand of general-purpose inverter, PLC communicates through MODBUS protocol.

Inverter frequency setting is given by PLC. The inverter supports MODBUS protocol. It can form 485 network with EC10 PLC. PLC adopts communication port 1 as communication port with inverter, and adopts common MODBUS RTU master-slave protocol for communication. PLC The master station is set to 1 and the inverter slave station is set to 2.
The following is the PLC master settings:

Inverter side communication parameter setting:
Table 2-1 Inverter Communication Parameter Settings

A brand communication protocol:
The frequency converter adopts an asynchronous serial master-slave MODBUS protocol. The data format of the communication protocol is divided into two communication formats: RTU (Remote Terminal Unit) and ASCII mode.
Communication with Emerson EC10 uses MODBUS RTU. In RTU mode, the format of each byte is as follows:
Coding system: 8-bit binary, hexadecimal 0-9, A-F Each 8-bit frame field contains two hexadecimal characters.

In RTU mode, the frame is always silent with a transmission time of 3.5 bytes as a start. The RTU data format is:

According to the communication description of a brand of inverter, the function code of the universal inverter is as follows:

The frame format is: Station No. Function Code (03H) Start Address High Start Address Low Data Count High Data Count Low CRC Low CRC High Bit

Therefore, if the host computer communicates with the frequency converter, the protocol frame is as follows:

Station No

function code

Start address high

Low starting address

High number of data

Low number of data

2

03H

3000H high

3000H low

0

2

The protocol frame for rewriting the frequency of the communication frequency converter is as follows:

function code

Start address high

Low starting address

High data

Low data

2

06H

2000H high

2000H low

High frequency

Low frequency

Emerson PLC communication:

The communication frame function part can compose the data into communication frames through the word data transmission instruction (MOV), starting from D302 to D307. Emerson's MODBUS protocol automatically adds CRC after the communication frame, eliminating the need for the user to calculate CRC checks.

SM135: Communication Port 1 MODBUS Communication Completed
SM124: Serial Port 1 Idle Flag
SM136: Communication error of communication port 1 MODBUS

Using the flag bit for communication interlock, the MODBUS instruction sends a data string and receives data into the D7970.

Third, the summary <br> Through the modular programming and PLC dual communication port function, the function of a medium-sized machine is easily realized on the minicomputer, realizes all the functions of the block forming machine process requirements, and reduces the customer's cost.

references
[1] Emerson PLC Programming Reference Manual