TDG配米控制系统英文说明书.doc

TDG-seriesRice-mixing PC Control SystemInstructions ManualZhangzhou Yujie Electronics Co., LtdTDG-P Series Continuous Auto Rice-mixing Machine1. OutlineTDG-P Series Continuous Auto Rice-mixing Machine is a kind of intelligentized equipment that uses the latest electronic machinery technique and can weigh and control the materials automatically during the production. It can be in blending production with kinds of materials (more than two kinds) and widely apply to rice process, feed, medicine, and chemical industry etc.The series of products use the industrial control computer and variable-frequency control system, which has the charateristics of advanced technique, rational construction, easy operation, convenient installation, stable and reliable running etc. It is a kind of ideal equipment for accomplishing to continuous measuring and auto blending production.2. Main characteristics and technical parameters(1) It provides the instantaneous/total flow data of kinds of materials and has the function of auto alarm and shutdown etc in starving procedure.(2) The belt mode quantitative feeding machine configures the high-accurate weighing load cell, electronic digital instrument. It can be set the proportion at will and will not damage the materials.(3) It uses the frequency control transmission system that can be in manual feed and auto control feed etc.(4) The human-computer interface is easy to operate.(5) Main technical paramters: different series have a little differeces, see the advertisement of our company in detail.3. Work principleThe auto matching system is composed of multiple electronic belt scales, conveyor and PC console etc. When the materials go through the electronic belt scale, the high-accurate weight sensor transforms the weight variation to the corresponding electronic signal, and collects the weight data and the RPM pulse tested by the sensor and sends them to the computer on the console. The computer figures out the instantaneous flow and total flow and compares the instantaneous flow with the demanded value, and sends out control signal to frequency converter according to the calculated difference. To achieve the purpose of auto matching, the frequency converter auto adjusts the transporting speed of belt scales to make them work with the matching ratio at the same time. If it is necessary to do manual running, you can set and run by using the manual switch and speed governing potentiometer on the console. When starving, the displayer will appear alarm indication and output auto shutdown control signal, the principle diagram (single station) is shown in Picture 1.Picture 1 Priciple diagram4. Belt scaleThe belt scale of TDG-P syetem is mainly composed of load cell, frequency converter, weighing instrumnet, feed belt and hopper etc. This kind of structural style has the advantages of high weighing accuracy, smooth speed governing, small and light, easy to adjust and maitain etc. There is a gate on the hopper that is used for regulating the thickness of materials. The structure is shown in Picture 2.Picture 2 Structrural scheme of the belt scaleInstantaneous flow measuring: when the feed belt runs with speed V and the materials on the belt is distributed evenly, the instantaneous flow is:F=V*G/L=Kc*G*VG is the weight displayed by the instrumentV is the linear velocity of belt (measured by CD instrument)Kc is the transport coefficient of belt scale Kc=1/LL is the effective length that belt scale bear the materials5. PC consoleThe console is used for measuring the weight and detecting the RPM. It figures out the flow of materials on belt scale and compares with the theorical flow set by user, and output 0-10V voltage according to the difference. It is also used for controlling the variable-frequency governor in belt scale, and real time control the transsimision speed of belt scale to make the flow of belt scale be equal to the theorical value, to accomplish to controlling the quantitative feeding. The console controls multiple belt scale at the same time so that can accomplish to the rice-mixing control according to the team production and matching.The console also matched the “manual/auto” running switch, conveyor starting and running button, auto running light, and ex-error alarming light. It also has manualrunning frequency-adjust potentiometer, even though there is no computer, it can also work by manual operating.6. Preparation before production(1) Check each connect lines if correct, when ready, turn on the main supply of control cabinet.(2) Turn on the industrial control computer, now the computer starts, start the software mainform.(3) Turn the “manual/auto” corresponding to each station of control cabinet to “manual” position.(4) Calibrate the weight display of CD instrumnet and set FUN11 in “2”.(5) Calibrate the linear speed V of belt scale.(6) Set up the parameter of team production and material matching parameter in each station.(7) Set up the alarm parameter and PID control paramter.7. Production steps(1) When all the preparation is ready, connect the power supply; turn the potentiometer knob to minimum and press starting button of all the conveyors to make them start to work. And then open the hopper gate, widen the gate which has high matching ratio, in contrast, narrow the hopper gate.(2) First rotate the potentiometer manually to go constant production before workingTurn the “manual/auto” switch on the operating panel to “manual” position, now it comes into manual operating state. Regulate the potentiometers corresponding to the each belt scale slowly until the frequency value of converter reaches to the need, then the belt scale will run with the setting frequency.(3) When the belt is starting, it comes to auto productionChoose “Auto” in the mainform and click “Boot-strap”, and then turn the “manual/auto” switch on control operating panel to “auto” position, now the belt scale starts to run automatically. The computer will display the corresponding proportion coefficient, theorical flow, real time weight of each belt scale, instantaneous flow and RPM, the converter displays the frequency value. When the material weight value changes, the frequency value will also change, and the transsmision speed of belt sclae will follow to change, to accomplish to feeding pro rata.(4) Ex-error alarm function:When one material overruns error (so-called overrun error is that the highest output frequency of belt scale or output frequency or output voltage is less than limited value, or the weight exceeds the limited value) and exceeds the limited time, the computer will appear alarm indicate for words, the alarm light on the console is on, the buzzer rings, to make operator pay attention or do manual intervention.Disposal method: when the starving causes ex-error, you can rise the hopper gate or power on until the materials increase; when the too heavy materials cause the too low frequency and send out the alarm, you can lower the hopper gate or change the matching ratio.8. Zero adjust and quantizing of belt scale (operation CD940 instrument)(1) Zero adjust:First clear the things on the belt scale, and then press【Set】one time to display “FUN1”, press【+】one time to display “FUN2”, and press【Enter】to display internal code, press【-】after several seconds the swing light is off. And after several seconds displaying “0.00” it returns to display internal code, so it is successfully reset. Press【Enter】one time to quit zero adjust function and it displays “0.00”, the reset operation is completed to date.(2) Weight adjust:First set up the weight value of balance for calibration, and press【Set】one time to display “FUN1”, press【Enter】to display “000.00”. Suppose the balance weight is 20KG, press【Shift】one time and press【+】tow times to display “20.00”, and press【Enter】to save the setting value and it displays “FUN1”. Now press【+】one time to display “FUN2”, and press【Enter】to display internal code, now clear the leftover in scale body and press【-】to reset after several seconds the “Swing” light is off, it will return to display internal code after displaying “0.00” several seconds, so it is successfully reset and the reset operation is completed to date; now put the 20KG balance onto the scale body and keep it steady without shaking, (now the internal code also increases a certain value accordingly, if the internal code dicrease instead, it shows that the signal wire of sensor is oppositely connected, just exchange) press【+】to do quantization after several seconds the “Swing” light is off, it will return to display internal code after several seconds displaying “20.00”, the quantizing operation is completed to date. Press 【Enter】to quit weight adjust function and it displays “20.00”, now take away all the balances, the instrument displays “00.00”, it shows that the quantizing is successful, or operate once more.9. RPM test of the belt scaleClick the “Settings” in the menu bar of the computer mainform, it appears the pull-down menu (the right picture), choose “Belt scale transport coefficient setting” and it appears the interface in the following picture: Picture 4Picture 5(1) Use the speed test function to test the speed: (tick “” in the left-hand corner of Picture 5). Picture 6Set Kn value of each scale in 1, as following picture shows: Picture 7Speed test formula: the belt scale speed V=Kn1*speed test data of the instrumentWhen the parameter is set up and saved, return the mainform, now turn the “Manual/auto” to manual, turn on the power of No.1 scale, rotate the manual potentiometer of No.1 scale and keep in one position to make belt RPM constant. Now, see how much the belt running speed (the right picture) is on the mainform. For instance, the displaying value V1=8m/s, record this value, the corresponding Kn is 1; and then manually measure the time T that the belt sclae takes a turn cost by stopwatch (measure it more times and get the average value), suppose T=8 seconds, the belt perimeter L1 is 3.2 meter, so the real linear speed V2=L1/T=3.2/8=0.4m/s, and the real Kn value should be: Kn=real linear speed V2/display speedV1=0.4/8=0.05, as a result, change the Kn value of No.1 sclae (Picture 4 shows) to 0.05, and measure the Kn value of other station by the same way.(2) The belt RPM is converted by variable-frequency voltage: (not tick “”) Picture 9When cancel “”, the Kn value will auto change to the corresponding value. Set the Kn value in 1, as the following picture shows: Picture 10The calculating method of Kn value is the same as the one of speed test, reference to the previous part.Speed calculating formula: running speed of the belt sclae V=Kn2*RPM amend*variable-frequency output valueGenerally speaking, the RPM amend is set in 1, just amend it when there exists deviation between the tested speed and real value, as the picture shows: Picture 1110. Introduction of maching control softwareThe matching console uses the industrial control computer, if coordinates with the control software developed by our company, it can accomplish to controlling the parameter setting, data display and control signal output, and achieve the purpose of auto maiching control.The main working interface of the control software is shown in Picture 12:Picture 12 Mainform of the control softwareMainform It can display the working parameter set by user: team production and matching ratio of each belt scale are shown in Picture 13:Picture 13 It can dynamically display the running data of belt scale: the weight value, setting flow value, instantaneous flow value, belt running speed value and variable-frequency output value of each belt scale are shown in the following picture:Picture 14 It matches the manual and auto button and boot-strap button for users: Picture15There is the pull-down menu in the mainform for users to choose, as Picture 16 shows:Picture 16 Pull-down menu(1) Team production and matching settingBefore working, the team production should be set according to the real situation, and the matching of belt scale must be set with users technical demand, but dont outstrip the work ability of the equipment. Click the “Setting” button in the mainform (Picture 17) and it appears that Picture 18 shows:Picture 17Picture 18When the above parameters are all set up and the flow unit has been chosen, click Confirm to save the setting parameter and it auto generates the setting flow of each belt scale (the right picture).(2) Belt scale transport coefficient setting:Click the “Settings” in the mainform and choose “Belt scale transport coefficient setting”, it appears that Picture 20 shows: Picture 20Belt scale Kc value: before the matching is taken in use, you should check the Kc value to ensure the accuracy demand of total flow. Kc calculating formula: Kc=1/L.L is the effictive length that the belt scale bear the materials, namely, the distance from feed opening to discharge hole.Picture21When in measuring, the effective length L will cause man-made error and measuring error, so you should do fine-regulation to Kc. The regulating method is as followings:After the belt scale is reset, first figure out a Kc value according to the measuring value, and put it in the parameter settings of main program. Now turn the “Manual/auto” on the console to “manual” and turn on the power of No.1 scale motor, rotate the manual potentiometer of No.1 scale and keep in one position to make the belt RPM constant. And then put a certain weight G1 materials into the hopper until the G1 materials are all sent out. Now check the total value G2 displayed by the instrument if be equal to G1, if not, when G2G1, increase Kc value; when G2G2, dicrease Kc value. Adjust it until G2=G1, the Kc value calibration is completed. Calibrate the Kc value of other belt scales by the same way.The RPM coefficient and RPM amend value should be set by experienced technician. Reference to Part 9 to see the detail.(3) Alarm settingUsers can set the upper and lower limit parameter of belt scale and frequency converter and alarm control parameter according to the actual situation. Click the “Settings” in the mainform and choose “Alarm setting” in Pull-down menu, it appears that Picture 24 shows: Picture 23 Picture 24Choosing the weight alarm and then shutdown will be favourable for protecting the system if it appears unusual in production.(4) PID parameter settingPID parameter is used for regulating the stability of variable-frequency control, regulate this parameter properly if the control is unstable or in shake. Click the “Settings” in the mainform and choose “PID paramter setting” in pull-down menu, it appears that Picture 25 shows.Proportion coefficient Kp, integral coefficient Ki and differential coefficient Kd are the three important parameters in PID calculation, the larger they are set, the more timely the flow will trace, but the fluctuation will be large and easy to cause shake; the smaller they are set, the slower the flow will trace, but the fluctuation will be small, the production will be stable and not easy to cause shake.The control cycle Tcy is the time interval in the second control. It is generally set in 2-3 seconds. Picture 25The control step limit is the max. value everytime the frequency output, the smaller it is set, the more favourable it will be for avoiding the control system causing shake. It is generally set in 2-4 Hz.(5) Set output original valueClick the “Settings” in the mainform and choose “Set output original value” in pull-down menu, it appears that Picture 26 shows: Picture 26Output original value: just choose “Auto” in the program mainform and click “Boot-strap”, it is the frequency value that first output when the system starts to run automatically. You can make timelag according to the setting delay time. When the main program runs, only the “Manual/auto” on the outer electric control cabinet is turn to “auto” can the system run automatically, but if so, PID will start to calculate from 0 and always cause shake and fluctuation, which make the system unstable. Therefore, setting the output original value can solve this problem.(6) Total flowClick the “Settings” in the mainform and choose “Total flow setting” in pull-down menu, it appears that the following picture shows: Picture 27Total flow is mainly used for watching all the flow and working time of the system and the total flow of each belt scale. If user wants to update the statistics, just click “Clear the total flow” button, the system will clear the original total parameters and begin to make the statistics again. “Record interval time” can not be set too small, or the database will be more and more large.(7) Password settingClick the “Settings” in the mainform and choose “Reset password”, it appears that the following picture shows: Picture 28In order to prevent the parameter setting error from leading to the abnormal work, it should be charged b