10384 200129005 UDC _ Product Lines and their Control System Design for Fine Powder and Ultra-fine Powder 2004 5 2004 6 2004 2004 5

AUTOCAD PLC PC PLC PC PLC PLC VB6.0 PLC VB PID I

MATLAB PID PLCCPU PID PLC PID II

Abstract Abstract The development of modern technology calls for strict requirements for powder granularity uniformity, and powdery material and products with excellent quality are costly and greatly needed by a variety of trades, which proves the bright future of pulverizing trade. In the cooperation with an enterprise, two product lines are designed according to its requirements and actual workshop layout, and the control system for the lines are redesigned, at the same time, it is discussed to how to realize powder granularity closed-loop control. Firstly, High Pressure Mill and Jet Mill are selected as the main pulverizing machines respectively for products of deferent granularity, so are the auxiliary equipments. And based on the selection and producing flow, two product lines for fine-powder and ultra-fine powder are designed. Overall layouts and erection drawings are designed suiting the factory actual conditions with AUTOCAD. Secondly, a control system for the two lines is designed to realize automatic-control. Two PLCs are adopted as lower-microcomputers to control the two lines and PC are adopted as upper-microcomputer to offer human-computer interactive interface and control the PLCs. PC and PLCs are linked together by link adapter to form host link system and the communication between them are achieved through SYSMAC WAY. With the development of ladder programs, PLC can control the product lines, including manual operation and single-machine trial, automatic-startup, automatic-stop, and running control. Based on VB6.0, human-computer interactive interface and programs for communication between computer and PLCs are designed. The III

Abstract human-computer interactive interface is to offer a window for the operator to control the machines, including operation mode selection, operation parameters setting, running condition examination, user confirmation, and user s management, etc. In the communication program, host link commands are adopted for PC to read parameters monitored by PLC and running records of PLC. The parameters are converted to decimal data and saved in databases, while the intraday parameters are depicted by curves. Thirdly, it is discussed to how to realize powder granularity closed-loop control based on PID control rule. According to force equilibrium of granularity in the vortex formed by the classifier, transfer function of the classifier is calculated. Based on this, System mathematical expression is modeled according to frequency converter and speed regulation motor transfer functions. PID control parameters will be selected with MATLAB simulation by observation of system dynamic performance. Thus, powder granularity closed-loop control will be realized by PID instruction of PLC CPU unit. Keywords: Fine-powder; Product Line Design; PLC; Automatic-control; PID Control. IV

... 1 1.1... 1 1.1.1... 1 1.1.2... 1 1.2... 3... 4 2.1... 4 2.2... 4 2.2.1... 4 2.2.2... 6 2.3... 6 2.4... 8... 12 3.1... 12 3.1.1... 12 3.1.2... 13 3.2... 13 3.2.1... 13 3.2.2... 15 3.3... 17 3.3.1 PLC... 17 3.3.2 OMRONCJ1... 19 3.3.3 PC... 20 3.4... 20 V

... 22 VI 4.1... 22 4.2... 23 4.2.1 PLC... 23 4.2.2... 25 4.3 PLC... 28 4.3.1 PLC... 28 4.3.2 CX-Programmer... 29 4.3.3... 30 4.3.4... 32... 40 5.1... 40 5.2... 41 5.3 PLC... 43 5.3.1... 43 5.3.2... 43... 46 6.1... 46 6.2 PLC... 55 6.2.1... 55 6.2.2... 57 6.3 VB6.0... 58 6.3.1 VB6.0 MSComm... 58 6.3.2... 60 6.4... 65 6.4.1... 65

6.4.2 PLC... 67 PID... 68 7.1 PID... 68 7.1.1 PID... 68 7.1.2 PID... 69 7.2 PID... 72 7.2.1... 72 7.2.2 PID... 73... 77... 79 VII

CONTENT CONTENT CHAPTER 1 INTRODUCTION...1 1.1 TASK SOURCE AND RESEARCH SIGNIFICANCE... 1 1.1.1 task source... 1 1.1.2 research significance... 1 VIII 1.2 MAIN RESEARCH IN THE THESIS... 3 CHAPTER 2 PRODUCT LINES DESIGN FOR FINE POWDER AND ULTRA-FINE POWDER...4 2.1 CONCRETE REQUIREMENTS OF THE MANUFACTURER FOR PRODUCTS... 4 2.2 MEATEIALS PULVERIZED METHOD SELECTION... 4 2.2.1 materials pulverized method description... 4 2.2.2 materials pulverized method selection... 6 2.2 EQUIPMENT SELECTION... 6 2.3 PRODUCT LINES DESIGN... 8 CHAPTER 3 AUTOMATIC-CONTROL SYSTEM OVERALL DESIGN FOR PRODUCT LINES...12 3.1 CONTROL OBJECTS INTRODUCTION... 12 3.1.1 control objects of fine powder product line... 12 3.1.2 control objects of ultra-fine powder product line... 13 3.2 CONTROL SYSTEM STRUCTURE... 13 3.2.1 PLC typical network... 13 3.2.2 control system structure... 15 3.3 HARDWARE SELECTION FOR CONTROL SYSTEM... 17 3.3.1 PLC selection... 17

CONTENT 3.3.2 OMRONCJ1 serial PLC introduction... 19 3.3.3 PC selection... 20 3.4 ANTI-JAMMING MEASUREMENTS... 20 CHAPTER 4 AUTOMATIC-CONTROL SYSTEM DESIGN FOR FINE POWDER PRODUCT LINE...22 4.1 CONTROL REQUIREMENTS... 22 4.2 SYSTEM HARDWARE STRUCTURE... 23 4.2.1 PLC input and output components adoption... 23 4.2.2 system hardware wiring diagrams... 25 4.3 PLC SOFTWARE DEVELOPMENT... 28 4.3.1 PLC program development method description... 28 4.3.2 CX-Programmer introduction... 29 4.3.3 main program development for control system... 30 4.3.4 subprogram development for control system... 32 CHAPTER 5 AUTOMATIC-CONTROL SYSTEM DESIGN FOR ULTRA-FINE POWDER PRODUCT LINE...40 5.1 CONTROL REQUIREMENTS... 40 5.2 HARDWARD WIRING DIAGRAMS FOR CONTROL SYSTEM... 41 5.3 PLC SOFTWARE DEVELOPMENT... 43 5.3.1 main program development for control system... 43 5.3.2 subprogram development for control system... 43 CHAPTER 6 HUMAN-COMPUTER INTERACTIVE INTERFACE AND COMMUNICATION PROGRAM DESIGN...46 IX

CONTENT 6.1 HUMAN-COMPUTER INTERACTIVE INTERFACE DESIGN... 46 6.2 COMMUNICATION PRINCIPLE BETWEEN UPPER-COMPUTER AND PLCS... 55 6.2.1 sysmac way... 55 6.2.2 communication parameters set... 57 6.3 COMMUNICATION PROGRAM DESIGN BASED ON VB6.0... 58 6.3.1 vb6.0 communication widget MSComm... 58 6.3.2 serial communication software design for control system... 60 6.4 PROGRAMS DEBUG... 65 6.4.1 programs debug for fine-powder line... 65 6.4.2 PLC ladder programs debug for ultra-fine powder... 67 CHAPTER 7 DISCUSSION ABOUT PID CONTROL APPLICATION IN GRANULARITY LOOP-CONTROL...68 7.1 PID CONTROL METHOD INTRODUCTION... 68 7.1.1 PID control principle... 68 7.1.2 PID digital control method in common use... 69 7.2 GRANULARITY LOOP-CONTROL DISCUSSION BASED ON PID... 72 7.2.1 loop control system structure... 72 7.2.2 PID parameters set... 73 CHAPTER 8 CONCLUSION AND EXPECTATION...77 REFERENCES...79 X

1.1 1.1.1 2002H102 (20 ) ( 200 90%) ( 325 90%) 0.1 ) 1.1.2 [1~9] 1.1.2.1 1

5µm 1.1.2.2 PLC PC 2

1.2 PLC VB6.0 PID MATLAB PID PLCCPU PID 3

2.1 4 300 2000 5000 / 300 2.2 [9~10] 2.2.1

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