1.Electronic Control System
It consists of Temperature Control and Measurement System, Action Control System, Computer System, and Software System.
1.1 Main Features
Electrical control system: the whole design of system adopts distributed control system composed of industrial control computer and PLC. Industrial Control Computer performs process setting, dynamics monitoring, and process management, and PLC executes the specific measurement and adjustment, as to achieve automation and flexibility of the overall equipment control system eventually, which also can set the individual process without industrial control computer. Computer control system has the prepared Ethernet communication interface, which is easy to link with other control system, as to achieve the centralized management and control of factory system.
Industrial Computer Control System: It is equipped with PC, Power supply and printer, which has the high reliability and anti-interference. The following functions can be achieved, such as system overall picture, parameter settings/display, temperature curve, information display, print, alarm system and on-line help. The system is Chinese, which is easy to operate.
Overall System View: Various colors and configuration components (i.e.: indicating light and analogue parts) forms system schematic diagram.
Parameter Setting Interface: The following items can be input and modified, i.e. date, shift, and operator’s name, code number of work-piece, process number, material, process temperature, process time and frequency. All of parameters can be spot using, back-up and file.
Parameter Display Interface: Displays the real time operating status of the whole system and measurement value of each key parameter visually.
Temperature Curve Interface: Real time Record the temperature and display the temperature curve with the time change. All of data can be used, reviewed and analyzed at anytime, as well as can be filed and printed.
Information Display: It is for controlling the alarms and easy to manage and maintain the equipment hardware.
Print Interface: Temperature curve interfaces, actual process parameters and information reports can be printed as needed or on a regular basis.
Alarm System: It includes parameter failure alarm, safety alarm of combustion system. automatic ignition and flame detecting device are equipped for each burner, when the burner is off, it will send alarm signal and cut off the control valve, and the indicating light will indicate where is the failure at, as well as the bell will ring to remind the operator to solve the problems timely. Besides, the alarm record will be output in the PC system.
On-line Help: Provide the system introduction and operating instructions.
1.2 Temperature Control System
This solution and aging production line is divided in 10 heating zones. (in which, solution furnace has 5 zones, and aging furnace has 4 zones, and quenching tank has one zone. ) Temperature of each zone is individually controlled.
Temperature controller is imported from Honeywell Company. It gets the feed back from the thermocouple and outputs 4~20mA signals to executor, the air and oil ratio valve will adjust the gas supply based on the air supply. Air and oil ratio valve will open the oil valve gradually based on the opening of butterfly valve, and to make each burner is fired completely. When the burner controller works, ignites the burner through the ignition transformer, meanwhile, the solenoid valve opens. If the flame detector electrode tracks the flame signal within a certain time, burner will work normally, otherwise, the gas solenoid valve will be shut off immediately and send out alarm signal. Each burner is controlled independently. During combustion, burners is featured with flame detection and fire-off alarm function.
All temperature control instruments and thermocouples must provide with Testing Report.
1.3 Temperature Recorder:
There are two paperless recorder of PHN type (imported from Fuji, Japan) to record the temperature of each temperature zone.
These recorders adopt high resolution liquid crystal to display temperature in curve, bar graph, data, reading, history curve, etc. All those data is accumulated in Mini-chip (CF Chip, Record data of 3 years) and can be printed out.
1.4 Mechanism Control System
A Siemens S7-300 PLC collects the position signal, start/stop signal from the site, and send out the tasks to control the system and operated in automatic or manual mode. The PLC should reserve with 10% of capacity for future update.