Asenkron makina otomasyonu ve bir bant taşıma sisteminin otomasyonunun projelendirilmesi

Başlık çevirisi mevcut değil.

Tez No: 66877
Yazar: OZAN ARAY
Danışmanlar: PROF. DR. NURDAN GÜZELBEYOĞLU
Tez Türü: Yüksek Lisans
Konular: Elektrik ve Elektronik Mühendisliği, Electrical and Electronics Engineering
Anahtar Kelimeler: Belirtilmemiş.
Yıl: 1997
Dil: Türkçe
Üniversite: İstanbul Teknik Üniversitesi
Enstitü: Fen Bilimleri Enstitüsü
Ana Bilim Dalı: Elektrik Mühendisliği Ana Bilim Dalı
Bilim Dalı: Belirtilmemiş.
Sayfa Sayısı: 238

Özet

ÖZET Bu çalışmada asenkron makinanın ve asenkron motorlardan oluşan bir bant taşıma sisteminin otomasyonunun projelendirilmesi yapılmıştır. Yazılan software SIEMENS firmasının programlanabilir otomasyon cihazlarından olan SIMATIC ailesine ait S5-155U PLC cihazında çalışacak şekilde tasarlanmıştır. Cihaz seçimi, hardware çalışma ve software çalışmayı içeren bu projenin tüm aşamaları mühendislik açısından özel uzmanlık gerekmektirmektedir. Otomasyonu yapılacak proses, asenkron motorlardan oluşan, yonga levha tesisine ait bir bant taşıma grubudur. Bu grubu oluşturan asenkron motorlardan 1 tanesi çift diğerleri ise tek yönlüdür. Motorların otomatik, manuel ve lokal çalışma modları bulunmaktadır. Otomatik çalışma şeklinde gruba ait motorlar tek bir grup start komutu ile devreye girip grup stop komutu üe durmaktadırlar. Manuel modda ise motorlar prosesin belirlediği sıra ile oparatör tarafından motorlara ait butonlar üzerinden yol alırlar. Yani bu modda da gruba ait software kilitlemeler aktiftir. Bu çalışmada da grup otomatik olarak korunmaktadır. Bir motor herhangi bir arıza nedeni ile durduğu zaman, arkasındaki bu motorun tahrik ettiği banta malzeme döken diğer motorlar da otomatik olarak duracaklardır. Arıza giderildikten sonra verilecek bir grup start komutu ile duran motorlar devreye girerek üretime devam edeceklerdir. Lokal modda ise bir kilitleme veya sıra aktif değildir. Çünkü bu mod bakım çalışma şeklidir ve oparatör istediği motoru sahadaki mahalli pano üstünden anahtarı lokal konuma getirerek devreye alıp çıkartabilir. Bu çalışmada yazılan software tüm bu koşullan gerçekleştirmekte ayrıca motorlara ait özel korumaları ve kontrolleri de sağlamaktadır. Hardware çalışmada ise motorların panolarının dizaynı, korumaları ve software için kullanılacak adreslerin belirlendiği çalışma yapılmıştır. Panolardan PLC cihazının dijital giriş ve çıkış modüllerine yardıma kontak veya sensörler üzerinden yapılacak olan bağlantılar bize software için taşman sinyalleri dolayısıyla da software içinde kullanılacak adresleri de belirlemiş olur. Bu hardware ve software' in nasıl yapıldığının açıklaması ve gerçeklemesi gereken fonksiyonların araştırılması, açıklaması ve tesbitleri bu tezin temelini oluşturmaktadır. PLC ile yapılan otomasyonla konvansiyonel sistemlerde karşılaşılan problemlerin çoğunun ortadan kaldırıldığı buna ek olarak da prosesin çalışmasında yapılması istenen değişikliklerin bağlantı değişiklerine ihtiyaç duyulmadan software yolu ile kolayca değiştirilebildiği ve motorun çift yönlü olmasının başka bir yazılıma gerek duymadan 2 tane ayrı tek yönlü motor olarak düşünülmesi ile de aynı software ile çalıştırılmasının mümkün olduğu savunulmuştur. XI

Özet (Çeviri)

SUMMARY In this study it is defended that by the comparison of the automation made with the PLC and the classic convantionel system, many problems have been removed by using the PLC and it is observed that in the case of an overhaul it is very easy to change it through the overhaul of the written software. There is no need of changing the connections as it is made in the convantionel system. The field of industrial automation is very large therefore the PLC's which will be used in this sector must have some common facilities. These facilities and their explanations can be read below. Through this job, the functions and the equipment of the programmable controller have been explained. They are the most important subjects that must be learnt by everyone before working with the PLC. The programmable Controller shall have a modular design. And a wide range of individually combinable modules shall be available for expansion. A system comprises:. Power supply module (PS): To connect the PLC to a 120/230 V AC or 24 V DC power source.. Central processing units (CPUs): Several CPUs are available for various performance ranges. A central controller may contain multiple CPUs to enhance power.. Signal modules (SMs) for digital (DI/DO) and analog (AI/AO) input and output functions.. Communications processors (CPs) for bus-network connections and point- to-point connections.. Function modules (FMs), specializing in demanding tasks like counting.. Interface modules (IMs) for connecting central controllers and expansion units.. An AT-compatible computer to solve technological problems where time is of the essence. Usable as either a CPU or a function module. The automation computer expands the control system by adding an open software platform. It consists of an AT-compatible computer core based on the field-proven real-time multi-tasking operating system. The PLC must be suitable for universal use:. Maximum conformity with industrial standards thanks to high electromagnetic compatibility, acceptable ambient temperatures of up to 60° C and high resistance to shock and vibration. Modules may be plugged in and unplugged while under power. XII. The programmable controller has to meet national and international standards including DIN, UL, CSA, FM and ISO 9001 A simple packaging system makes the PLC versatile and easy to service:. Rack mounting: The modules are simply hooked onto a mounting rack, swung into position and screwed tight.. Backplane bus: The parallel I/O bus for high-speed data exchange with signal modules and function modules, is integrated into all racks. Except some types of the expansion racks, all racks have a serial communications bus for high-speed exchange of large quantities of data.. Easy module replacement without confusion: All that is required in order to replace modules is to loosen the mounting screws. Wired front connectors can be removed simply by unplugging. The polarization key on the front connector prevents the wired connector from being plugged into the wrong module type.. Field-proven connecting equipment: Connecting cables are connected to the process by way of screw-type connectors, crimp connectors or clamped connectors.. Defined mounting depth: All terminals and connectors are accommodated in recesses on the modules and protected by covers. This means all modules have a defined mounting depth.. No slot rules: All modules except power supply and interface modules in expansion racks can be plugged into any slot without restriction. CENTRAL PROCESSING UNIT CPU The CPU shall be programmable with an object orientated programming language. The comment set of the CPU shall contain the comments of the floating point operations. And a use of more than a single CPU in a rack shall be available. Powerful design features give the CPUs their high performance. A high performance CPU shall have the following features:. High-performance processors: The CPUs can execute a binary instruction in as little as 0,08 u\s.. Memory capacity: XIIILoad memory for user programs and parameterization data for the programmable controller; High speed RAM for executable program sections from the user program.. Key-operated mode selector: Access rights to user data can be restricted by removing the key.. Password protection: In addition to the key operated switch, a multi-level password concept protects the user program against unauthorized access.. Diagnostic buffer: The last 120 fault and interrupt events are retained in a ring buffer for diagnostic purposes.. Real-time clock: Diagnostic messages from the CPU are dated and stamped with a clock time.. Memory card: A memory card (RAM or Flash EPROM) is always needed to run the PLC. As we have mentioned above a PLC has these equipment for use. If a project of an automation is going to be made this subject must be read carefully in order to learn the structure and the function- of the PLC. In this study a SIMATIC PLC S5-155U is selected for the automation. There is a hardware and software study to be done. In software a programm is written with the adresses of the motors that are determined in the hardware study. The way how it is done in this study is explained below. Every connection made to the digital input and output modules becomes an adress which is used in software during programming. These adresses are determined in the hardware study. In this study, the motor control panels are designed and the electrical equipments which is responsible for their protection is selected. The power and signal cables of the motors, their contactors, thermic magnetic relays, thermistors, sensors for speed detectig are selected and the signals which have to be controlled in the PLC must be determined and drawn on the shematic diagrams. These signals are the connections made between the digital input and output modules and the motor control panels. For starting up of the motors their contactors must be energized. This done by the software because the conditions for energizing are defined in the software with the adresses which represent the sensors, thermic relays, start, stop buttons. If they fulfill the condition of start up the written software forces the proper output adress which represents the contactor of the motor to be logic 1 and through this, the digital output module gives 24 V DC to the related terminal on which the related motors contactor is connected. xivIf an example should given how it is done in the software and how the adresses used in the software are defined you must follow the steps below: 1) The list of the connections made by the digital input modules must be prepared. In this job the memory of the CPU begins to be loaded. 2) The list of the connections made by the digital output modules must be prepared. 3) The lists which contain all the signals are called signal lists and with the help of this the conditions can be programmed as below: Start Button: The adress 15.0 Thermic Magnetic Relay: They have free contacts for checking the position of the relay. If the normally open contact is connected to the digital input module an becomes the adress 15.1. This adress becomes only logic 1 if the relay is closed. Contactor KNTK: It is connected to the digital output module an has the adress for instance Q 5.3. The KNTK contactor is energized if Q 5.3 becomes logic 1. KNTK must be energized if the following conditions are fulfilled: a) The relay must be closed. Therefor the adress 15.1 must be logic 1. b) The start button must be pushed. Therefor the adress 15.0 must be logic 1. This conditions must now be programmed in the CPU. That's why a selection of the programming language must be done. A Ladder Logic language is the most easiest for programming. If the programm is wanted to be written in an other programming language for example as C it is possible with a C Compiler. SIMATIC offers us the step5 language for programming and in this ladder logic language we have some following opportunities for programming: Ladder diagrams Control System Flowchart CSF Statement list STL The programm written by using STL is as follows: A I 5.0 A I 5.1 = Q5.3 If the output signal Q 5.3 becomes log 1, the related motor must start up. As you can imagine this is not enough for the control. Because there is no feedback through with we can give decision that the motor is running or not. That's why there some conditions in which the contactor KNTK with the adress Q 5.3 must be deenergized. In some cases it is possible that the power cable of the motor is not connected or is becoming feeble. This must be controlled. For this case a sensor must be installed to the shaft of the motor for detecting if it is running or not. A time interval must be defined because of the safety reasons. If a signal is received during the defined time interval with the signal of the free contact of the contactor KNTK, it can be easily seen that the kntk is energized and the motor is in RUN mode. XVThe sensor which detects the shaft is a proximity switch which closes his normally open contact if a metal material comes closer. The material is fixed to the shaft and comes closer per turning to the sensor. And the sensor sends a signal called EDRW to the digital input card by closing its normally open contact. If all of these conditions are fulfilled in defined time intervals it can be said that the motor is in RUN mode without any error. As it is explained, for the control of each motor a software must be written with their own adresses determined in hardware study. If the programm is written directly with the motor adresses, the related programm must be written as much as the number of the motors. This is ofcource not logical because this way of programming takes enormous place in the memory of the CPU. A solution have been found for this by programming with formal parameters. By programming a function block with formal parameters, a software packet is created which can be called in the software where a motor is wanted to be programmed by the CALL FB command. By calling this function block the formal parameters are prepared for parametrazing with the proper motor adresses. In this way a one single programmed software module is created for continuous use. This way of programming provides us more place in the memory of the CPU. These FBs are the standard E-Module and G- Module in this study. After writing the standard modules they are addressed via the help of the hardware schematics. After it is finished, the delivered process must be programmed by programming the programming blocks. The most important part of the software is the CPU. Because the programm is loaded into the CPU. All comments used for programming is delivered by the CPU. The CPU selected for this study is the CPU 948. Therefore this CPU has to be learnt by the programmer. The CPU memory has some limits for the number of timers, counters, flags, inputs, outputs, s-flags which are used by programming. If a timer is used which is not defined in the CPU 948 it is impossible to start up the CPU. Therefore the limits must not be passed in the software. The programmer must separate the memory between the standard modules and the program block programming. The flag areas are especially important in this job. If the same flag which was used in the FB is used in a PB, the common used flag may get some unwanted values and cause the E-Module or G-Module to stop which can cause big dangers in a process. As it can easily be realized, an automation which is going to be projected with the PLCs needs a serious knowledge of hardware and software engineering. But this is not enough. The selection of the electrical equipments of the PLCs is as important as the other steps. All studies must be done with big attention because a little mistake or a little carelessness can cause serious dangers. XVI

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