Nadzorno-krmilni sistem v proizvodnji kalcijevo-karbonatnih polnil s pripravo podatkov za izračun lastne cene proizvedenega materiala

BELINA, IGOR (author), Nedeljković, David (mentor)

V diplomskem delu opisujem nadzorno-krmilni sistem dela proizvodnega postopka mokrega mletja kalcijevega karbonata in transportne poti končnega produkta v silose ter postopek priprave podatkov za izračun lastne cene materiala. Pri postopku mletja moramo poskrbeti za doziranje suspenzije v mlin, mazalni sistem reduktorja mlina in hladilni sistem motorja mlina. Transport zmletega končnega materiala v silose je sestavljen iz homogenizacije, filtriranja, hlajenja in prečrpavanja materiala v silose. Za izračun lastne cene materiala sem pripravil podatke na krmilnem nivoju in jih preko OPC strežnika ter aplikacije @Tropc prenesel v MS SQL bazo, kjer so na voljo za uporabo kalkulacije lastne cene materiala. Na krmilnem nivoju sem izvedel integracijo mlina in transportne poti v obstoječi krmilni sistem ter pripravil podatke za izračun lastne cene materiala. Za izvedbo sem uporabljal krmilno opremo Siemens CPU417 z dislociranimi enotami ET200M in ABB frekvenčnimi pretvorniki preko komunikacije PROFIBUS ter Siemens CPU319 z dislociranimi enotami ET200M in analizatorji moči SIMEAS. Preko ETHERNET komunikacije je izvedena povezava z nadzornim sistemom in OPC strežnikom. Vse enote so vezane na glavni industrijski usmerjevalnik. Za izdelavo krmilnega nivoja sem uporabil programsko orodje Simatic Step 7. Nadzorni nivo omogoča upravljanje posameznih aktuatorjev, zagon in ustavitev linij, alarmiranje, ter prikaz zgodovine dogodkov in meritev. Predstavil sem osnovne gradnike sistema, potek tehnološkega procesa in regulacij ter integracijo v obstoječi nadzorni sistem. Za izdelavo nadzornega sistema sem uporabljal programsko orodje Proficy HMI Ifix 5.1. Pri izdelavi projekta sem sodeloval z investitorjem, s katerim sem se dogovarjal o ceni, opremi in izvedbi projekta. Nadzoroval sem delo in terminski načrt izvajalcev pomožnih del ter odpravljal napake pri izvedbi del na projektu. Največji izziv projekta je bila integracija novih linij v konstantno delujoč sistem proizvodnje. Za zelo zahtevno se je izkazala natančna priprava podatkov za izračun lastne cene materiala, pri kateri je potrebno upoštevati vsak dogodek, ki se zgodi med proizvodnjo.

• Language: Slovenian
• Keywords: programirljivi krmilnik, nadzorni sistem, vodenje, mokro mletje, lastna cena materiala, integracija v obstoječ proces proizvodnje
• Work type: Undergraduate thesis
• Organization: FE - Faculty of Electrical Engineering
• Year: 2016
• PID: 20.500.12556/RUL-85157
• Publication date in RUL: 14.09.2016

Secondary language

• Language: English
• Title: Supervisory Control System in Calcium Carbonate Fillers Production with Data Preparation for Cost Price Calculation

Abstract

The thesis describes the control-monitoring system as a part of the production for wet grinding of calcium carbonate and transport routes to storage silos of the finished product. It describes the process of preparing the data for the calculation of the cost price of the material. The process of grinding is supported by the slurry feeder, the lubrication unit of the reduction gear of the mill and the water cooling system of the mill motor. The process of transport to the silos for finished material comprises of homogenizing the material, filtering and cooling the material and transportation of the material to the silos. The concept of data preparation for cost price calculation comprises of preparing data at the control level, the transfer of data via OPC server in the MS SQL database, where data are available for calculation of cost price for the material. At the control level I integrated mill for milling process and transport route at the existing control system. I also prepared data for calculation the cost price of the material. I used Siemens equipment CPU417 with dislocated units ET200M and ABB frequency converters via PROFIBUS communication and also I used CPU319 with dislocated units ET200M and power analyzer SIMEAS. The communication link is made via ETHERNET to the supervisory control system and OPC server. All units are connected to the main industrial ETHERNET switch. I used Simatic Step 7 software for programing the PLC. Supervisory control level is used for managing actuators, start and stop automatic procedures, managing alarms, logging data and overview of measurements. Presented in the thesis are basic building blocks, technology and controls, and integration into existing system. I used software Proficy HMI iFix 5.1. Within the project I cooperated with the investor, with whom I negotiated the price, equipment and project implementation. I was supervising the work and schedule of subcontractors and eliminated the errors in the project. The challenge was integration of new lines at continuous production. Exact data for the calculation of the cost price of the material, taking into account each event occurring during the production, was very demanding.

• Keywords: programmable controller, control system, supervisory system, wet grinding, the cost price of the material, integration into the existing production process