Lam Mat Clinker

n Tt Nghip
Ngnh iu Khin T ng
LI M U
Trn th gii hin nay, cc ngun nng lng t nhin nh than , du m, kh t ang dn cn kit do s pht trin nhanh chng ca cc ngnh cng nghip. Bn cnh vic s dng nhng thit b khng hp l v qu c cng gp phn gim nng sut v tng hao ph nng lng trong cc nh my. Do vn tm kim ra nhng ngun nng lng mi cng nh s dng hp l v tit kim nng lng ang rt c quan tm. Vic s dng cc thit b v gii php tit kim in dn tr thnh tt yu trong cc nh my, nht l cc nh my cng nghip ln. Vit Nam, trong hn 10 nm tr li y, vic trang b t ng ha cho cc nh my khng nhng nng cao nng sut, gim c s vt v cho ngi vn hnh m cn gp phn tch cc trong vic tit kim chi ph sn xut. Khng nm ngoi xu th , ngnh cng nghip xi mng nc ta, xut hin t thi k u ca thi i cng nghip, cng ngh sn xut cng tri qua nhiu giai on pht trin v ngy cng hon thin hn. Cc dy chuyn, trang thit b cung cp cho ngnh ang dn c t ng ha p ng cc ch tiu v k thut v mi trng kht khe cng nh trong vic tit kim chi ph gim gi thnh sn phm. Vi ti tt nghip ng dng bin tn tit kim nng lng cho h thng qut my lnh lm mt clinker trong nh my xi mng nhim v ca ca chng em l: - Tm hiu v nm vng quy trnh cng ngh sn xut xi mng t khai thc, nghin liu n ng gi sn phm v nhng c th ring ca nh my.
- Tm hiu cu trc nguyn l cng on lm mt clinker.

- Nghin cu s dng thit b : Bin tn, PLC v cc phn mm ng dng lin quan nh WINCC v STEP7 MICROWIN. - ng dng thit k h thng iu khin gim st cho cng on lm mt clinker. Chng em xin chn thnh cm n thy gio PGS.TS.Nguyn Don Phc , tp th nhn vin trong cng ty ASEATEC v ton th cc thy c gio trong b mn iu Khin T ng hng dn v gip chng em trong qu trnh thc tp v lm n tt nghip. Tuy nhin do cn hn ch v mt kin thc v thi gian, do vy mc d rt c gng nhng n ca chng em cng khng trnh khi nhng thiu st. Chng em rt mong nhn c s gp v b xung ca cc thy c gio. Sinh vin thc hin : V Hoi Nam V Vit Hng
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V Hoi Nam V Vit Hng : KT1 K49
n Tt Nghip
Ngnh iu Khin T ng
MC LC
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n Tt Nghip
Ngnh iu Khin T ng
DANH MC CC HNH
Hnh 1.1 : S tng quan dy chuyn cng ngh sn xut xi mng..........................12 Hnh 1.2 : S cng ngh cng on nghin phi liu v ng nht........................15 Hnh 1.3 : Silo hai tng...............................................................................................16 Hnh 1.4 : Silo trn u lin tc kiu bung trn ca Claudius Peter.........................17 Hnh 1.5 : S cng ngh cng on nung...............................................................18 Hnh 1.6 : S cng ngh cng on nghin xi mng...............................................20 Hnh 1.7 : S khi cng on nghin xi mng........................................................21 Hnh 1.8 : S cng ngh cng on ng bao xi mng..........................................22 Hnh 2.1 : H thng lm lnh kiu ghi.........................................................................25 Hnh 2.2 : H thng lm lnh kiu hnh tinh...............................................................26 Hnh 2.3 : H thng lm lnh l quay h t..............................................................26 Hnh 2.4 : M hnh my lm mt kiu ghi...................................................................27 Hnh 2.5 : Hnh nh bn trong bung l tunel.............................................................27 Hnh 2.6 : H thng ghi thp chu nhit.......................................................................28 Hnh 2.7 : Van iu chnh lu lng gi lm mt.......................................................29 Hnh 3.1: Nguyn l bin tn.......................................................................................31 Hnh 3.2 : S nguyn l MM 440............................................................................34 Hnh 3.3 : Cu to ca CPU PLC S7-200...................................................................52 Hnh 3.4 : Cc cng truyn thng v modul truyn thng ca S7-200........................53 Hnh 3.5 : Giao din ca phn mm STEP7-MICROWIN...........................................55 Hnh 3.6 : Cu trc ca Graphics Designer...............................................................62 Hnh 4.1 : Kin trc s lc ca OPC.........................................................................71 Hnh 4.2 : Kin trc Client/Server trong OPC............................................................72 Hnh 4.3 : S u ni dy gia PLC v bin tn....................................................75 Hnh 4.4: Kt ni ngun vi CPU S7-200...................................................................81 Hnh 4.5 : Ghp ni cp RS-232/PPI Multi Master..................................................82 Hnh 4.6 : Thit lp cc thng s truyn thng............................................................82
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n Tt Nghip
Ngnh iu Khin T ng
Hnh 4.7 : Ca s Communications ............................................................................83 Hnh 5.1 : Cu trc h thng iu khin......................................................................91 Hnh 5.2 : S nguyn l h thng iu khin..........................................................92 Hnh 5.3 : Mn hnh giao din qu trnh lc khi ng v ch dng..................97 Hnh 5.4 : Mn hnh giao din qu trnh khi hot ng..............................................98 Hnh 5.5 : Cnh bo khi nhit u ng gi nng 3 qu cao...................................99 Hnh 5.6 : Mn hnh trng thi ca qut lm mt (Fan 01)......................................100
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n Tt Nghip
Ngnh iu Khin T ng
DANH MC CC BNG
Bng 1.1 : Yu cu k thut ca nguyn liu trc khi vo my nghin......................13 Bng 1.2 : Thnh phn khong clinker theo tc lm mt.......................................19 Bng 1.3 : Ch tiu v sut tiu hao nng lng..........................................................23 Bng 1.4 : Ch tiu pht thi ra mi trng................................................................23 Bng 1.5 : Ch tiu v n nh cht lng sn phm...................................................24 Bng 3.1 : Cc u dy iu khin ca MM 440.........................................................33 Bng 3.2 : Cc u vo s ca MM 440......................................................................35 Bng 3.3 : Cc nt chc nng ca MM 440................................................................37 Bng 3.4 : Cc tham s thng dng ca MM 440.......................................................50 Bng 3.5 : Cu to phn cng ca mt s CPU S7-200..............................................51 Bng 3.6 : Yu cu cu hnh my tnh cho WinCC......................................................58
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n Tt Nghip
Ngnh iu Khin T ng
Chng I : CNG NGH SN XUT XI MNG PORTLAND

1.1. Khi nim chung v cc thnh phn ha hc ca xi mng :
Xi mng portland l kt dnh thy lc, khi trn vi nc s to h do c tnh kt dnh v ng rn c trong mi trng khng kh, mi trng nc. Xi mng portland l sn phm nghin mn ca clinker vi thch cao thin nhin, i khi cn pha thm vo mt vi loi ph gia khc nhm ci thin mt s tnh cht ca xi mng v tng sn lng, h gi thnh. Hin nay trn th trng c hai loi xi mng ph bin l : PC ( Portland Cement ) v PCB ( Portland Cement Blended ). Clinker sn xut bng cch nung n kt khi phi liu c nghin mn v ng nht gm hai nguyn liu chnh l vi v t st, ng thi c thm thch anh, qung st v mt s cht ph gia iu chnh. Bn xit chnh trong clinker xi mng l : CaO, SiO2 , Al2O3 , Fe2O3. T l cc xit c bn trong phi liu biu din thnh phn ha hc ca clinker, quyt nh tnh cht ca clinker, v cng l ch tiu quan trng nht kim tra v nh gi cht lng ca xi mng. Tng hm lng ca chng chim khong ( 95% 97% ) thnh phn cc cht trong clinker v thng thng t l cc xit ny trong clinker nh sau : CaO SiO2 : : 63% 67% 21% 24% 4% 8% 2% 4%
Al2O3 : Fe2O3 :
Ngoi cc thnh phn c bn , trong xi mng cn c ph gia l cc xit khc, c hm lng khng ln lm : MgO(1% 5%), Mn2O3(0 3%), SO3(0.1% 1%), TiO2, K2O, Na2O ...
1.2. Nguyn liu, nhin liu sn xut clinker xi mng :

1.2.1. Nguyn liu sn xut xi mng :
Hu ht cc nh my xi mng trn th gii u sn xut xi mng t hn hp phi liu nhn to. m bo thnh phn ha hc ca clinker ngi thng dng hn hp t hai nguyn liu chnh l vi v t st, ngoi ra cn c mt vi nguyn liu ph na nh qung bxit, lacterit, qung st, trepen, diatomit... 1.2.1.1. vi :
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n Tt Nghip
Ngnh iu Khin T ng
Sn xut clinker xi mng portland thng dng cc loi vi, phn... Cc loi ny thnh phn ch yu ca n l CaCO3, mt lng nh MgCO3 v mt t tp cht khc. Theo TCVN 6072-1996, vi dng lm nguyn liu sn xut xi mng portland phi tha mn yu cu v hm lng ca cc cht l : CaCO3 85%, MgCO3 5%, K2O + Na2O 1%. 1.2.1.2. t st : t st l loi nham thch trm tch, l nhng alumo silicat ngm nc c rt nhiu trong thin nhin. Thnh phn ch yu ca t st l SiO2, Fe2O3, Al2O3. Ngoi ra trong t st cn ln ct, si, sn v cc tp cht hu c. Theo TCVN 6071-1996, st dng lm nguyn liu sn xut xi mng portland phi c hm lng cc xit trong khong sau : SiO2 = 58 70%, Al2O3 = 10 24%, K2O + Na2O 3%. Cc nh my xi mng nc ta hu ht u s dng st i ( st ) c hm lng cc xit m bo yu cu. Mt s ni c th dng st rung hoc st ph sa nhng nhng loi st ny thng c hm lng SiO2 thp hn, Al2O3 v kim cao hn nn phi c ngun ph gia cao silicat b sung SiO2. 1.2.1.3. Mt s loi ph gia dng trong sn xut xi mng : Cc cht ph gia c a vo phi liu nung hoc nghin cng clinker nhm mc ch ci thin cng ngh nghin, nung hay thay i mt s tnh cht ca xi mng. Ngoi ra cn gp phn tng nng sut, h gi thnh sn phm : Ph gia khong ha : gim nhit nung clinker nhm tit kim nhin liu v tng kh nng to khong, tng hot tnh ca cc khong clinker. Mt s loi ph gia khong ha nh : qung fluorit, cn gi l hunh thch (cha CaF2), qung phosphorit (cha P2O5), qung barit (cha BaSO4), thch cao (cha CaSO4). Cc loi ph gia ny c th dng ring mt loi hoc dng phi hp vi nhau dng ph gia hn hp, khi tc dng khong ha s tt hn. Tuy vy, trong sn xut nu cng s dng nhiu loi nguyn liu v ph gia th cng ngh pha trn phi liu cng phc tp v tn km.
Ph gia iu chnh : Dng iu chnh s kt dnh v ng rn ca xi mng. Cc loi ph gia iu chnh chnh c s dng l : Ph gia giu silic (thng dng t hoc cao silic c SiO 2 > 80% hoc ct mn), ph gia giu st (thng dng x Pirit, qung st, qung Laterit), ph gia giu nhm (thng dng qung Bxit, cao lanh hoc tro x nhit in).
Ph gia thy : lm tng tnh cht bn nc ca xi mng.
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n Tt Nghip
Ngnh iu Khin T ng
Ph gia in y : nhm tng nng sut, h gi thnh sn phm.
1.2.2. Nhin liu s dng trong nh my xi mng :

Nhin liu s dng cho cc l trong cc nh my xi mng bao gm c nhin liu rn, lng, kh. Mun m bo nng sut sn xut cn cung cp y nhin liu cho cc l t c nhit yu cu, mun vy th nhin liu phi m bo : Cung cp nhiu nhit cho l. Nhin liu phi chy hon ton vi lng khng kh d nh nht. Dng khng kh nng a vo tng iu kin chy.
1.2.2.1. Nhin liu rn : Nhin liu rn c s dng y l than . Yu cu than phi c nhit lng cao 5500 Kcal/Kg, cht bc cao (15 30%), ngn la di, tro nhin liu t (10 20%), hm lng lu hunh nh. Than dng cho l quay l phi sy kh, nghin mn theo yu cu. 1.2.2.2. Nhin liu kh : Kh thin nhin c khai thc t di cc lp t su, n l nhng hp cht ca cc loi cacbuahydro hu hn khc nhau, ch yu l mtan, ngoi ra cn mt s kh khc nh tan, propan, butan, pentan. u im ca nhin liu kh l d t ng ha, khng cn qua giai on gia cng, lng lc. 1.2.2.3. Nhin liu lng : Nhin liu lng c s dng rt tt l mazut. Mazut thu c t sn phm sau khi chng ct du m. u im ca mazut l t tp cht, hm lng tro rt nh (khong 0,1 0,3%), m 1 4%, nhit nng kh cao ( > 8000 Kcal/Kg ). Tuy nhin vic s dng nhin liu lng l mazut cng c nhng nhc im : khng thun tin khi vn chuyn, rt v cha ng bo qun.
1.3. Cng ngh sn xut xi mng :

Qu trnh sn xut clinker xi mng gm 3 giai on : Giai on 1 : Gia cng, ng nht nguyn nhin liu v chun b phi liu. Giai on 2 : Nung hn hp phi liu thnh clinker v lm mt clinker. Giai on 3 : Gia cng, v nghin clinker vi cc ph gia khc. C hai phng php sn xut xi mng l phng php t v phng php kh. Hai phng php ny khc nhau ch yu giai on 1 v giai on 2 : Giai on 1 : C th gia cng phi liu theo phng php t hay kh.
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n Tt Nghip
Ngnh iu Khin T ng
Giai on 2 : C th nung hn hp phi liu trong l ng hay l quay. Vic la chn phng php sn xut ph thuc vo nhiu iu kin m ch yu l tnh cht c l, tnh cht ha hc ca nguyn liu, iu kin in nng, nhit nng, thit b Sau y l s tng quan v dy chuyn sn xut xi mng :
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n Tt Nghip
Ngnh iu Khin T ng
Hnh 1.1 : S tng quan dy chuyn cng ngh sn xut xi mng.
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Ngnh iu Khin T ng
1.3.1.Giai on 1: Gia cng, ng nht nguyn liu, nhin liu v chun b phi liu :
Vic chun b nguyn liu v hn hp phi liu sn xut clinker xi mng l mt khu quan trng, n nh hng trc tip n cht lng sn phm. Chun b nguyn vt liu phi qua cc cng on sau : 1.3.1.1. Khai thc v vn chuyn nguyn liu : vi v t st l hai ngun nguyn liu chnh, c khai thc theo phng php ct tng bng n mn hoc khoan. Sau dng xe i, my xc,a ln xe ti vn chuyn t cng trng khai thc v nh my. 1.3.1.2. Gia cng s b nguyn liu : vi l nguyn liu rn, c chuyn v nh my t cng trng khai thc, thng c kch thc 600 800mm, do cn c gia cng s b bng my p hm n kch thc 60 80mm, sau a vo my p ba. ra khi my ba c kch thc 5 25mm c a vo kt cha hoc sil. Cng c th s dng my p ba 2 trc ch p mt ln c kch thc 20 25mm. t st l loi nguyn liu mm, c th qua my cn trc ri a vo kt cha. Sau a vo my nghin bi nghin chung vi , nc hoc a vo my sy nghin lin hp phi liu. Nu t st c m cao th sau khi qua my cn trc c a vo b ba bn, bn ra khi b ba bn c m 60 70% c a vo b cha ri vo my nghin bi nghin chung vi . Khi sn xut xi mng theo phng php kh, nu nguyn nhin liu c m t nhin cao cn phi sy n m t yu cu trc khi a vo my nghin cng c th sy nghin lin hp. Yu cu k thut ca nguyn liu trc khi vo my nghin :
Tn nguyn liu vi t st X l cao Than
m t nhin (%) 3 7% 5 25 % 15 25 % 10 15 %
m vo my (%) <2% <2% <2% <2 3%
Bng 1.1 : Yu cu k thut ca nguyn liu trc khi vo my nghin. 1.3.1.3. ng nht s b nguyn liu :
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n Tt Nghip
Ngnh iu Khin T ng
Kho ng nht s b nhm mc ch d tr v cng cp nguyn liu cho my nghin liu. Cc nguyn liu th sau khi vn chuyn n kho bng cc bng ti thnh cc ng v lung khc nhau thun tin cho vic v ly nguyn liu. Ti kho ng nht s b c cc h thng gu ri nh ng nguyn liu thnh cc ng d tr. Ngoi ra cn c h thng cc gu xc a nguyn liu vo my nghin qua h thng bng ti. Cc phng php ng nht s b thng c s dng trong cng nghip sn xut xi mng l : phng php cht ng Chevron v phng php cht ng Windrow. 1.3.1.4. Qu trnh nghin liu : Mc ch ca my nghin liu l sn xut ra bt liu ng nht, cc tiu chun cho php nung tt trong l. Vic ny phi c thc hin mt cch kinh t nht, ng thi phi m bo cc yu cu : kch thc np liu, kh nng nghin nh, dnh v mi mn. Cc nguyn liu th t kho cha ng nht s b c cn trn bng ti gim st khi lng t, sau c trn vi ct thch anh v qung st vi thnh phn ph hp theo cng ngh ngay trn bng ti chnh trc khi vo my nghin. Trong my nghin, hn hp phi liu s c nghin mn. mn ca hn hp phi liu c nh hng rt ln n qu trnh nung luyn v cht lng clinker, mn cng cao b mt tip xc gia cc nguyn liu cng ln, qu trnh nung cng nhanh, cng c iu kin nng cao cht lng clinker. cng on ny, b phn ly lm nhim v kim tra mn ca phi liu. Nhng ht phi liu mn s c chuyn n sil FF/CF hoc a thng n thp tin nung. Nhng ht cha t tiu chun s c a tr li my nghin t mn cn thit. Phng phn tch ha nghim KCS lm nhim v ly mu v phn tch thnh phn ha hc ca mu iu chnh thnh phn cc nguyn liu u vo. Vic phn tch c thc hin theo chu k v hon ton t ng m bo cht lng ca xi mng.
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n Tt Nghip
Ngnh iu Khin T ng
Hnh 1.2 : S cng ngh cng on nghin phi liu v ng nht. 1.3.1.5. ng nht phi liu : Phi liu ra khi my nghin phi a qua cc thit b ng nht (Sil) c trn u, m bo ng nht v n nh ca phi liu trc khi a vo l nung. Nguyn tc ca vic ng nht phi liu l da vo p lc nht nh ca kh nn tin hnh trn u bt liu. Trn tm y sil lp t cc kiu thit b xung kh. Sau khi xung kh, trc tin lm lng bt liu, sau tin hnh trn theo trng thi dng chy lm cho thnh phn bt liu ng u. Do thit b xung kh khc nhau v cch b tr cng khc, dn n s khc nhau v phng php v cu to sil ng nht : a. Sil ng nht bt liu kiu gin on ( sil FF : dng qua phu ) : L loi sil m khi tin hnh ng nht phi chia bc gin on khi vo liu v ra thnh phm liu sng. Nguyn tc l s dng dng chy hnh phu : Rt nhiu lp hnh nn c vo sil v c trn mt cch lin tc. Khi sil cn, bt liu c tho ra qua mt knh hp. Mt l hnh nn c to ra trn b mt ca bt liu v liu trt xung cc cnh ca hnh nn ri ra khi sil. Bt liu c phn phi u gia hai sil trn bn trn, m cc lp bt liu cng
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n Tt Nghip
Ngnh iu Khin T ng
mng cng tt. Cp liu l nung c rt ra t mt trong hai sil bn di. Khi mt sil trn y th sil kia mi y na. Sil y c tho ra nhanh chng v sil kia c dng tr trng. Khi mt sil tr cn th vic rt liu c chuyn sang sil kia. H thng sil FF khng ph thuc vo vic trn bng kh nn nn nng lng tiu th thp, ng thi trnh c nguy c phn tch. Tuy nhin nu bt liu dnh th hiu qu ng nht thp. C 3 loi sil FF : Sil 2 tng. Sil xp snh i. Sil trn n thun.
Ch thch : 1. Kh nn. 2. Mng trt kh ng. 3. Lc bi ti. 4. Thit b bo y. 5. Sc kh nn. 6. Kh cao p. 7. Bnh bm cao p. 8. Cp liu sng. 9. Van cp liu.
Hnh 1.3 : Silo hai tng. b. Sil ng nht kiu lin tc ( sil CF : dng chy c iu khin ) :
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Dng chy trong h thng sil CF c iu khin bng cch tho liu qua nhiu ca ra y sil v c tin hnh nhiu mc dng chy khc nhau. Sau trn cc bt liu t cc ca ra ring r trong mt b trn l tng, nh. y ca sil c chia thnh 7 khu vc c 6 cnh ging nhau. gia ca mi khu vc c mt l m b phn tho y bng mt hnh nn thot p sut. Mi khu vc li chia thnh 6 phn hnh tam gic, tt c u c lp hp thng gi xp. cc l m b phn tho lp c cc van, t cc van ny bt liu c chuyn bng kh trt n b trn y sil. C cc loi sil CF : Sil trn u bt liu kiu lin tc khoang hn hp. Sil trn iu khin nhiu dng im. Sil trn iu khin khng ch dng lin tc. Sil kiu bung trn ca Claudius Petes. Sil ng nht ca Claudius Petes. Sil ng nht lin tc ca Polysius. Sil ng nht kiu a dng ca Polysius. Sil ng nht kiu im a dng ca LSF. Sil bung trung tm ca IBAU. Sil ng nht lin tc ca PARTER.
Ch thch : 1. 2. 3. 4. Lc bi ti. ng cp liu. Bung trn. Phn t sc kh.
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Hnh 1.4 : Silo trn u lin tc kiu bung trn ca Claudius Peter.
1.3.2.Giai on 2: Nung hn hp phi liu thnh clinker v lm mt clinker:
Hnh 1.5 : S cng ngh cng on nung. 1.3.2.1. L nung v thp tin nung : Cng on l nung l cng on quan trng nht trong qu trnh sn xut xi mng. Trong di tc dng ca nhit t vic t chy nhin liu, cc qu trnh l ha xy ra i vi bt liu to thnh clinker. Cng on l yu cu hot ng l n nh, kim sot c s c cng nh p ng c cc yu cu v cht lng v sn lng, cng v l do m nung clinker xi mng s dng l quay ph bin hn l ng. Thp tin nung c 5 tng, gm 5 sil ng nht. Mi sil c chia thnh 2 tng : tng 1 ng nht v tng 2 dng cha bt liu. Liu c th c tho t tng 1 ca sil th nht sang tng 2 ca sil th 2 hoc c th tho trc tip xung tng 1 ca sil . Ngoi ra thp cn c h thng dn kh u cho. Nguyn tc hot ng ca thp 5 tng l liu t trn i xung ng thi kh nng c ly t l nung c dn t di ln trn. Khi phi liu t trn xung, n c sy ln lt v cng i xung di nhit sy cng cao. Qua h thng thp 5 tng, phi liu c sy s b n gn 1000 oC trc khi vo l nung.
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Nhin liu nung l bt than c phun p sut cao di dng m. Nguyn tc cp liu cho l nung l bt than c thi vo v t t ui l, cn phi liu c xung t h thng sy 5 tng xung u l. Dng kh nng i ngc t ui l n u l. Phi liu cyclone qua sy 5 tng c sy s b i vo l nhit tng dn lm cc phn ng pha rn xy ra v c kt khi 1300 oC n 1450 oC to thnh clinker. Khi nung clinker trong l quay, thi gian lu vt liu trong dn kt khi khong 20 25 pht vi nhit nung 1300oC n 1450oC th qu trnh to khong xy ra hon ton. Nu nhit nung qu cao, hm lng pha lng qu ln th clinker c th to thnh nhng cc ln, nh hng n s vn chuyn ca vt liu trong l v nng sut l. Nu lu vt liu trong dn kt khi vi thi gian qu ngn, qu trnh to khong s xy ra khng hon ton, cht lng clinker gim. Nu ko di thi gian lu vt liu th mt s khong s phn hy trong khi nung, nng sut l gim, thu c clinker kh nghin, tn nhit nng. Cht lng clinker c nh gi s b da vo kch thc ht clinker, mu sc v dung trng ca n. 1.3.2.2. Lm mt clinker : Clinker sau c a qua h thng my lm mt clinker. Lm mt clinker l mt giai on quan trng trong qu trnh sn xut clinker, n nh hng n cht lng sn phm. Mc ch gim nhit ca clinker c to ra. Tc lm mt clinker c nh hng n s kt tinh cc khong v hm lng pha thy tinh trong clinker : Nu lm mt chm, sn phm ng rn s khng n nh th tch, lm gim cht lng clinker. Nu lm mt nhanh, sn phm ng rn n nh th tch hn, cht lng clinker tt hn. Thnh phn khong clinker ph thuc tc lm mt clinker : Tn khong C3S C2S C3A C4AF Thy tinh clinker Thnh phn (%) cc khong clinker khi lm mt theo tc Chm 59.8 18.5 12.8 6.1 0 Trung bnh 65.2 14.5 8.0 6.1 0 Nhanh 65.2 9.2 0 0 22.4 Rt nhanh 70.0 3-4 0 0 20.6
Bng 1.2 : Thnh phn khong clinker theo tc lm mt.
1.3.3. Giai on 3 : Gia cng, v nghin clinker vi cc ph gia khc.

1.3.3.1. clinker : Clinker ra khi thit b lm mt c a vo cc sil cha trong khong 10 15 ngy trc khi a ti cng on nghin. Mc ch :
17
n Tt Nghip -
Ngnh iu Khin T ng
Tip tc lm ngui clinker n nhit thng.
- To iu kin cho cc khong tip tc kt tinh, lm sn phm sau ny n nh th tch khi ng rn. Clinker dn, d nghin.
t c nhng mc ch trn, ngi ta cn phun nc dng sng m vo clinker mi ra l, nh vy hiu qu lm ngui clinker nhanh hn, rt ngn thi gian . Ngoi nhng l do trn, cn khng cho php nghin clinker nng v thu c sn phm c nhit qu cao, nh hng n vic ng bao b. Mt khc nghin clinker qu nng, nng sut my nghin s gim, nh hng n thit b trong my nghin v gim tc dng iu chnh tc ng rn xi mng ca thch cao. 1.3.3.2. p clinker v ph gia : Trc khi a clinker v ph gia vo my nghin cn tin hnh gia cng s b bng cch p th clinker v ph gia trong my p hm n kch thc t yu cu. Ngi ta c th p clinker ngay sau khi ra khi l nung ri mi a vo . p clinker v ph gia trc khi nghin vi mc ch : Tng nng sut my nghin. Trnh c nhng ch tc s c khi nghin.
Thc t cho thy kch thc cc clinker vo my t 8 10mm, nng sut my nghin tng ln 10 15%. Nu kch thc cc clinker vo my t 2 3mm, nng sut my nghin tng ln 25 30%. 1.3.3.3. Nghin clinker v ph gia trong my nghin :
Hnh 1.6 : S cng ngh cng on nghin xi mng.
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n Tt Nghip S khi :
Ngnh iu Khin T ng
Hnh 1.7 : S khi cng on nghin xi mng. y chnh l cng on nghin xi mng : Clinker, thch cao v ph gia (ph gia thy, ph gia iu chnh,) trong cc kt cha c tho qua mt h thng van v cc cn nh lng ri vo h thng bng ti 2 chiu a vo my nghin. Bi ton phi liu c thc hin thng qua h thng cn bng nh lng, nh hn hp nguyn liu trc khi vo my nghin s c m bo v t l cc thnh phn ph hp vi chng loi xi mng cn sn xut. Di tc ng tr xt ca vt liu nghin trong my nghin ( cc loi bi st ) nguyn liu s c nghin nh ra v t ti mt mn theo yu cu. My nghin ngoi tc dng nghin mn hn hp trn cn c tc dng trn u, ng nht hn hp bt mn to thnh xi mng. Cng xi mng, tc rn ph thuc nhiu vo nghin mn ca bt xi mng. Xi mng nghin cng mn, qu trnh ng rn cng nhanh v cng cng cao. Xi mng ra khi my nghin c a qua b phn ly, ti y c s sng lc : Nu xi mng t tiu chun th c tch ring a n sil cha qua h thng bng ti. Nu ht xi mng qu ln th c thu hi v a tr li my nghin nghin li cho ti khi t yu cu. Mt phn xi mng ra khi my nghin cng c thu hi bi h thng lc bi tnh in. Vi cng ngh lc bi tnh in, my lc bi s thu hi cc ht xi mng bm trn cc bn cc tnh in ri chuyn n cc silo cha xi mng nh bng ti. 1.3.3.4. ng bao : Xi mng t y cc sil xi mng c th c xut ra ngay, gi l sn phm xi mng ri. Cng c th xi mng c tho ra v a ti dy chuyn ng bao b t ng thu c sn phm xi mng ng bao.
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n Tt Nghip
Ngnh iu Khin T ng
Hnh 1.8 : S cng ngh cng on ng bao xi mng.
1.4. c im c bn ca dy chuyn cng ngh sn xut xi mng:

Tnh phc tp ca cng ngh sn xut : Dy chuyn sn xut xi mng gm nhiu cng on sn xut cng nh ph tr. Trong cng on sn xut c bn nht l cng on nung clinker. Thit b y thc hin mt qu trnh trao i nhit lin tc. Qu trnh bin i ha hc v c l mnh m din ra trong mt h thng thit b cng ngh kh phc tp, gm nhiu tng v nhiu khi chc nng hot ng lin hon. Cc cng on nghin liu, nghin than, nghin xi mng l nhng h thng thit b c chu trnh kn, hot ng tng i c lp. Tiu th nng lng ln : Cc my mc chnh trong dy chuyn sn xut xi mng u thuc loi cng sut ln, tiu th nhiu nng lng. Vi cng ngh hin i, sut tiu hao nng lng trung bnh khong 750 Kcal/Tn clinker, sut tiu hao nng lng cho nung clinker l 60 KWh/Tn clinker v cho nghin xi mng l 35KWh/Tn xi mng. Vn hnh ch di hn : Hu nh tt c cc thit b my mc cng ngh u lm vic ch di hn trong 3 ca sn xut. Phn b rng v bao che kn : Cc thit b cng ngh trong dy chuyn c ghp ni vi nhau thnh nhiu vng bng cc ng ng gi cng ngh, thit b lc bi v cc h thng thit b vn chuyn. Tnh bin ng ngu nhin ca tham s cng ngh : Cc tham s l ha ca nguyn liu th dao ng trong di rng, do phn b t nhin ca cc v - lp v v tr ca cc
20
n Tt Nghip
Ngnh iu Khin T ng
m nguyn liu khc nhau, do ch c th xc nh c tham s c th sau khi khai thc. Tnh bin thin chm ca tham s cng ngh : Cc qu trnh bin i tnh cht c, l, ha trong cc cng on sn xut xi mng l nhng qu trnh bin thin chm, h thng thit b cng ngh c cng sut ln v c qun tnh rt ln.
1.5. Cc ch tiu cn t c trong qu trnh sn xut xi mng :

Cc ch tiu theo TCVN 6016 : 1995 ; EN196 nh sau :
1.5.1. Ch tiu v sut tiu hao nng lng :

STT Ch tiu n v KWh/ T Ch s 10 25
1 Sut tiu hao cho nghin nguyn liu 2 Sut tiu hao nhit nng cho nung clinker 3 Sut tiu hao in nng cho nung clinker 4 Sut tiu hao in nng cho nghin xi mng
Kcal/ Kg 700 850 KWh/ T KWh/ T 37 45 30 38
Bng1.3 : Ch tiu v sut tiu hao nng lng.
1.5.2. Ch tiu pht thi ra mi trng :

STT 1 2 3 4 Ch tiu pht thi Bi v c Nox SO2 CO n v mg/m3 mg/m3 mg/m3 mg/m3 Ch s 50 1200 750 50
Bng 1.4 : Ch tiu pht thi ra mi trng.
1.5.3. Ch tiu v n nh cht lng sn phm : 21

n Tt Nghip STT A 1 2 3 4 5 6 7 8 B 1 2 3 4 mn Thi gian kt thc ng kt gin n bn nn sau 28 ngy CaO SiO2 Al2O3 Fe2O3 MgO SO3, Mn2O3 K2O Na2O C l Ch tiu Ha hc
Ngnh iu Khin T ng n v Ch s
% % % % % % % %
65 68 20 23 4.0 6.0 2.0 4.0 1.0 6.0 0.1 3.0 0.1 1.0 0.1 0.5
cm3/g h mm N/mm2
3200 3600 2.0 4.0 1.5 0.5 45 55
Bng 1.5 : Ch tiu v n nh cht lng sn phm..
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n Tt Nghip
Ngnh iu Khin T ng
Chng II : CNG ON LM MT CLINKER

2.1. Mc ch :
Mc tiu ca cng on lm mt l h nhanh nhit ca clinker sau khi ra khi l nung lm tng hot tnh ca cc khong clinker, thu hi nhit thi ( gi III, gi II ) cp kh nng cho vi t calciner v my nghin than, cng nh ti clinker n my p nh ri a ln vo mt sil hoc cc sil cha cho cng on tip theo. Nh nu trn, tc lm mt clinker c nh hng n s kt tinh cc khong v hm lng pha thy tinh trong clinker qua nh hng trc tip n cht lng ca xi mng. Ty theo c im cng ngh cng nh nng sut ca nh my m la chn cng ngh lm mt ph hp :
Hnh 2.1 : H thng lm lnh kiu ghi.
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Ngnh iu Khin T ng
Hnh 2.2 : H thng lm lnh kiu hnh tinh.
Hnh 2.3 : H thng lm lnh l quay h t.
2.2. Cng ngh lm mt clinker kiu ghi :

2.2.1. Cu to chung ca my lm mt kiu ghi :
Thit b thng c s dng ch yu trong cc nh my xi mng l my lm mt clinker hiu sut cao ca Polysius hoc ca Claudius-Peters.
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n Tt Nghip
Ngnh iu Khin T ng
Hnh 2.4 : M hnh my lm mt kiu ghi. Cu to chung ca my lm mt kiu ghi gm c cc b phn chnh sau y : 2.2.1.1. Bung my : Bung my hnh l tunel c hai ca thot kh : Mt ca u l v mt ca cui l thu hi gi nng II v gi nng III. Cui bung my l my p s b, gip gim bt kch thc ca clinker sau khi ra khi bung l.
Hnh 2.5 : Hnh nh bn trong bung l tunel. 2.2.1.2. Ghi thp chu nhit : y l b phn chnh to ra c cu chuyn ng ti clinker i trong l :
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n Tt Nghip
Ngnh iu Khin T ng
Hnh 2.6 : H thng ghi thp chu nhit. Cc ghi thp chu nhit c lp thnh hng ngang bung my, c mt hng ghi tnh xen mt hng ghi ng. Chc nng ca hng ghi ng l ti clinker i dc theo l tunel v pha trc. Cn chc nng ca hng ghi tnh l cho khng kh lnh t cc qut p lc chui qua cc khe h ca ghi qut mt. Ton b chuyn ng ca h thng ghi c to ra l nh s dng cc xylanh thy lc c lp t bn di. H thng cc ghi c lp nghing dc xung di ( t 3-4o ) d ti clinker n my p ba. Trc y ph bin l my lm lnh ba cp ghi thp. Hin nay ngi ta ci tin c cu ghi tt hn v hiu sut lm ngui clinker, cng nh tt hn v bn nhit v bn n mn c hc nn my lm ngui clinker ch cn hai cp vi dc hp l ca ghi. 2.2.1.3. Qut lm mt : H thng lm mt s dng cc qut p lc cng sut ln c lp t hai bn hng my ( l tunetl ). S lng qut t 9 n 11 ci vi tng lu lng c thit k theo nh mc 1.8-2.2 m3/kg clinker. p lc cc qut khng ging nhau nhng lu lng gi phi p qua cc khe h ca ghi v chui qua chiu dy ca lp clinker trong qu trnh lm mt v thu hi nhit ca clinker. Vic iu chnh lu lng gi lm mt c thc hin nh h thng iu khin m ca cc van gi. Cc van gi l cc c cu chp hnh, c iu khin bi cc ng c servo v h thng iu khin ring. Khi no cn lu lng gi lm mt nhiu, van s m nhiu v ngc li.
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n Tt Nghip
Ngnh iu Khin T ng
Hnh 2.7 : Van iu chnh lu lng gi lm mt. Cc thit b cn li ca cng on lm mt clinker l my p clinker, bng ti, gu xch a clinker ln vo sil cha, my lc bi tnh in v sil cha clinker. My p clinker c th l my p ba, my p cn p hai trc, ba trc, c th l my p hm ty theo nng sut l.
2.2.2. Nguyn l lm vic ca my lm mt kiu ghi :

Nguyn l lm vic ca my mt clinker kiu ghi thp l : clinker t phu rt xung tri rng khp trn din tch ghi vi chiu dy 250-350mm. Nh s chuyn ng ca h thng ghi thp, clinker c ti dc theo l tunel v pha trc. ng thi khng kh lnh t cc qut p lc chui qua cc khe h ca ghi qut mt v ly nhit ca lp clinker ri thot ra theo ng thu hi kh nng ( gi III ) n cp cho vi phun ca bung phn hy carbonat. Hai ca thot kh ca l tunel s thu hi nhit lng ta ra : Ca u l thu hi nhit ca clinker t 1200-1300oC xung 600800oC. Ca thot th hai cui l thu hi kh nng 300-400oC. Kh nng thu qua ca ny mang i cp cho my nghin than. nh gi hiu sut lm ngui ca cc model my lm mt clinker thng cn c vo cc ch tiu :
1. Nhit ca clinker ra khi my lm mt : Hin nay t c trn 65oC

so vi nhit mi trng.
2. Hiu sut thu hi nhit ca my lm mt. 27

n Tt Nghip
Ngnh iu Khin T ng
3. Lu lng khng kh lnh cp cho my lm mt clinker bng cc qut

gi ca my. Ch s lu lng ca kh lnh thng l 1.8-2.2 m3/kg clinker. Ch s lu lng cng gn 1.8 th hiu sut lm mt cng tt. Ngoi ra hiu sut lm mt ca my lm mt clinker c ch tiu chi tn in nng ( kWh/tn clinker ) cng t cng tt. Tng t, nh gi v bn ca cc ghi thp : bn nhit, kh nng truyn ti clinker
2.3. xut gii php tit kim nng lng :

Nh trnh by trn, cc qut lm mt lun chy tc nht nh cung cp mt lng gi lm mt n nh. Vic iu chnh lu lng gi theo yu cu ca h thng lm mt c thc hin nh thay i m ca cc van. Do , c mt phn khng nh lng gi to ra khng c a vo h thng lm mt, ng ngha nng lng tiu tn to ra lng gi b lng ph. Gii php xut y l thc hin iu chnh lu lng gi vo lm mt bng cch iu chnh ngay tc ca cc ng c. Qua tit kim c phn nng lng lng ph trn, cng chnh l ci thin tiu ch tiu tn in nng, nng cao hiu sut lm mt ca my lm mt. Phng n xut l s dng h thng ghp ni PLC v bin tn iu khin tc ng c. M rng ra c th thit k giao din HMI iu khin gim st qu trnh.
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n Tt Nghip
Ngnh iu Khin T ng
Chng III : GII THIU V MT S THIT B V PHN MM NG DNG

3.1. Bin tn MICROMASTER 440 (MM440) :
3.1.1. Nguyn l hot ng ca bin tn :
Bin tn l thnh qu ca s pht trin k thut vi iu khin v k thut bn dn. Bin tn c th c s dng cho nhiu mc ch khc nhau nhng bin tn t c hiu qu cao nht trong ng dng iu khin v cp tc ng c p ng cc yu cu v cng ngh. Ty vo vic ng dng bin tn trong nhng lnh vc iu khin khc nhau m hiu qu ca n mang li cho ngi ng dng th hin cc mt khc nhau. Nguyn l lm vic ca b bin tn kh n gin. u tin, ngun in xoay chiu mt pha hay ba pha c chnh lu v lc thnh ngun mt chiu. Cng on ny c thc hin bi b chnh lu cu diode v t in (t DC link). Nh vy, h s cng sut cos(j) ca h bin tn c gi tr khng ph thuc vo ti v bng t nht l 0.96. in p mt chiu ny c bin i (nghch lu) thnh in p xoay chiu ba pha i xng. Cng on ny hin nay c thc hin thng qua h IGBT (transistor lng cc c cng cch ly) bng phng php iu chnh rng xung (PWM). Nh tin b cng ngh vi x l v cng ngh bn dn cng sut hin nay, tn s chuyn mch xung c th ln ti di tn s siu m nhm gim ting n cho ng c v gim tn tht trn li st ng c.
Hnh 3.1: Nguyn l bin tn H thng in p xoay chiu ba pha u ra c th thay i gi tr bin v tn s v cp ty theo b iu khin. Theo l thuyt, s bin i tn s v in p phi tun theo mt lut nht nh ty ch iu khin. i vi ti c m men khng i, t s in p tn s l khng i. Tuy vy vi ti bm v qut, lut ny li l hm bc
29
n Tt Nghip
Ngnh iu Khin T ng
4. in p l hm bc 4 ca tn s. iu ny to ra c tnh m men l hm bc 2 ca tc ph hp vi yu cu ca ti bm/ qut do bn thn mmen cng li l hm bc 2 ca in p. Hiu sut chuyn i ngun ca cc b bin tn rt cao v s dng cc b linh kin bn dn cng sut c ch to theo cng ngh hin i. Nh vy, nng lng tiu th xp x bng nng lng yu cu bi h thng.
3.1.2. Cc u dy iu khin v s nguyn l :

u dy 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 K hiu ADC1+ ADC1DIN1 DIN2 DIN3 DIN4 ADC2+ ADC2DAC1+ DAC1PTCA PTCB DIN5 DIN6 DOUT1/NC DOUT1/NO Chc nng u ngun ra +10V u ngun ra 0V u vo tng t-s 1(+) u vo tng t-s 1(-) u vo s-s 1 u vo s-s 2 u vo s-s 3 u vo s-s 4 u ra cch ly +24V/max 100A u vo tng t-s 2(+) u vo tng t-s 2(-) u ra tng t-s 1(+) u ra tng t-s 1(-) u dy ni cho PTC/KTY84 u dy ni cho PTC/KTY84 u vo s-s 5 u vo s-s 6 u ra s s 1/ tip im NC u ra s s 1/ tip im NO
30
n Tt Nghip 20 21 22 23 24 25 26 27 28 29 30 DOUT1/COM DOUT2/NO DOUT2/COM DOUT3/NC DOUT3/NO DOUT3/COM DAC2+ DAC2P+ N-
Ngnh iu Khin T ng u ra s s 1/ chn chung u ra s s 2/ tip im NO u ra s s 2/ chn chung u ra s s 3/ tip im NC u ra s s 3/ tip im NO u ra s s 3/ chn chung u ra tng t-s 2(+) u ra tng t-s 2(-) u ra cch ly 0V/max 100A Cng RS485 Cng RS485
Bng 3.1 : Cc u dy iu khin ca MM 440.
31
n Tt Nghip
Ngnh iu Khin T ng
Hnh 3.2 : S nguyn l MM 440.
32
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Ngnh iu Khin T ng
3.1.3. Cch ci t tham s ca bin tn :

3.1.3.1. Ci t mc nh : B bin tn MICROMASTER 440 c ci t mc nh khi xut xng sao cho c th vn hnh c m khng cn ci t thm bt k thng s no na. t c iu ny, cc thng s ca ng c c kt ni vi bin tn phi c thng s nh mc ph hp vi thng s ci t mc nh (P0304, P0305, P0307, P0310) tng ng vi ng c 1LA7 4 cc ca Siemens (hy xem cc thng s nh mc ghi trn nhn).
Cc ngun lnh P0700 = 2 (u vo s) Ngun im t P1000 = 2 (u vo tng t) Ch lm mt ng c P0335 = 0.

Gii hn dng in P0640 = 150% Tn s nh nht P1080 = 0 Hz Tn s ln nht P1082 = 50 Hz Thi gian tng tc P1120 = 10 s Thi gian gim tc P1121 = 10 s Ch iu khin P1300 = 0
u vo/ u ra u vo s 1 u vo s 2 u vo s 3 u vo s 4 u vo s 5 u vo s 6 u vo s 7 u vo s 8
Cc u ni 5 6 7 8 16 17 Qua u tng t s 1 Qua u tng t s 2
Thng s P0701 = 1 P0702 = 12 P0703 = 9 P0704 = 15 P0705 = 15 P0706 = 15 P0707 = 0 P0708 = 0
Chc nng ON/OFF1 - (I/O) o chiu Xa li im t c nh im t c nh im t c nh Khng s dng Khng s dng
Bng 3.2 : Cc u vo s ca MM 440.
33
n Tt Nghip 3.1.3.2. Truyn thng qua BOP : Nt Chc nng Hin th trng thi Khi ng b bin tn
Ngnh iu Khin T ng
ngha Mn hnh LCD hin th cc ch ci t hin hnh ca b bin tn n nt ny lm cho b bin tn khi ng. Nt ny khng c tc dng mc nh Kch hot nt : P0700 = 1 hoc P0719 = 10...16
Dng b bin tn
OFF1 : n nt ny khin ng c dng theo c tnh gim tc c chn. Kch hot nt: hy xem nt Khi ng b bin tn. OFF2 : n nt ny hai ln (hoc n mt ln v gi mt khong thi gian) khin ng c dng t do. BOP: Nt ny lun lun c tc dng (khng ph thuc vo thng s P0700 hoc P0719)
o chiu
n nt ny lm ng c o chiu quay. o chiu c hin th bng du(-) hoc im chm nhy. Nt ny khng tc dng mc nh Kch hot nt: hy xem nt Khi ng b bin tn .
Chy nhp ng c
trng thi sn sng chy, khi n nt ny, ng c khi ng v quay vi tn s chy nhp c ci t trc. ng c dng khi th nt ny ra. n nt khi ng c ang lm vic khng c tc ng g. Nt ny c th dng xem thng tin : Khi ta bm v gi khong 2 giy nt ny hin th cc thng tin sau bt u t bt k thng s no trong qu trnh vn hnh 1. in p 1 chiu trn mch DC (Hin th bng d n v V) 2. Dng in ra (A) 3. Tn s ra (Hz) 4. in p ra (hin th bng o n v V) 5. Gi tr c chn bng thng s P0005 (Nu nh P0005 c ci t hin th bt k thng tin no trong s cc thng tin t 1 4 th gi tr ny khng hin th li) n thm s lm quay vng cc gi tr trn bng hin th. n gi
Nt chc nng
34
n Tt Nghip
Ngnh iu Khin T ng trong khong 2 giy quay v ch hin th thng thng. Chc nng nhy
Nt chc nng
T bt k thng s no (v d nh rxxxx hoc Pxxxx), n nhanh nt Fn s ngay lp tc nhy n r0000, sau ngi s dng c th thay i cc thng s khc nu cn. Nh kh nng quay v r0000, n nt Fn s cho php ngi dng quay tr v im ban u. Gii tr Nu c xut hin cc cnh bo v cc thng bo li th cc thng tin ny c th c gii tr bng cch bm nt Fn
Truy nhp thng s Tng gi tr
n nt ny cho php ngi s dng c th truy nhp n cc thng s n nt ny lm tng gi tr c hin th
Gim gi tr n nt ny lm gim gi tr c hin th
Bng 3.3 : Cc nt chc nng ca MM 440. 3.1.3.3. Ci t thng s : ( Ci t thng s nhanh ) B bin tn tng thch vi ng c nh s dng chc nng ci t thng s nhanh, v cc thng s quan trng s c ci t. Ci t nhanh khng cn c thc hin nu thng s nh mc ca ng c ghi trong b bin tn FU ( v d ng c tiu chun 1LA 4 cc ca Siemens) thch hp vi thng s nh mc ghi trn nhn ca ng c ang ni vo bin tn.
Bt u
P0003=3
Mc truy nhp ca ngi dng* 1 1. Mc c bn: Cho php truy nhp n nhng thng s thng dng nht 2. M rng : V d truy nhp n cc chc nng I/O 3. Chuyn gia: Ch dnh cho chuyn gia
35
n Tt Nghip
P0004=0
Ngnh iu Khin T ng
P0010=1
P0100 =
Lc thng s * 0 0. Tt c cc thng s 2. Bin tn 3. ng c 4. Cm bin tc Ci t thng s * 0 0. Sn sng 1. Ci t nhanh 30. Ci t ti nh my Ch : P0010 nn c 1 ci t thng s nh mc trn nhn ng c Tiu chun chu u / Bc M 0 0. Chu u [KW], tn s mc nh 50Hz 1. Bc M [hp], tn s mc nh 60Hz 2. Bc M [KW], tn s mc nh 60Hz Ch : i vi P0100=0 hoc 1, gi tr P0100 c xc nh khi ci t kha chuyn DIP 50/60 OFF = KW, 50Hz ON = hp, 60Hz ng dng b bin tn 0 (Nhp vo kiu momen yu cu) 0. Momen khng i (v d thang my, my nn, my gia cng) 1. Momen bin i ( v d bm, qut) Ch : Cc thng s ny ch c tc dng i vi b bin tn trong h truyn ng 5.5 KW/ 400V Chn kiu ng c 1 1. ng c khng ng b 2. ng c ng b Ch : i vi P0300 = 2 (ng c ng b), ch c php iu chnh V/f (P1300 < 20) in p nh mc ng c Thng s FU in p nh mc [V] ghi trn nhn ca ng c.
P0205=
P0205=
P0300=
P0300=
P0304=
P0304=
36
n Tt Nghip
Ngnh iu Khin T ng
P0305= P0307=
P0305= P0307=
P0308
P0308
P0309
P0309
P0310=...
in p nh mc ghi trn nhn phi c kim tra, t bit c cu hnh Y/ m bo ph hp vi cch ni mch trn bng u ni ca ng c. Dng in nh mc ng c Thng s FU Dng in nh mc [A] ghi trn nhn ca ng c. Cng sut nh mc ng c Thng s FU Cng sut nh mc [KW/hp] ghi trn nhn ca ng c. Nu P0100=0 hoc 2 gi tr tnh theo KW Nu P0100=1 Gi tr tnh theo hp H s cos nh mc ng c Thng s FU ) ghi trn nhn. H s cng sut nh mc (cos Nu nh ci t l 0, gi tr c t ng tnh ton Nu P0100=0 th P0308 khng c ngha, khng cn nhp Hiu sut nh mc ng c Thng s FU Hiu sut nh mc ca ng c theo [%] c ghi trn nhn Ci t l 0, gi tr c tnh ton bn trong Nu P0100=0 th P0309 khng c ngha, khng cn nhp Tn s nh mc ng c 50.00Hz Tn s nh mc ca ng c c tnh theo [Hz] ghi trn nhn S i cc c t ng tnh ton li nu thng s thay i. Tc nh mc ng c Thng s FU Tc nh mc ca ng c c tnh theo[v/ph] ghi trn nhn Ci t l 0, gi tr c tnh ton bn trong Ch : Cn phi nhp thng s trong trng hp iu khin vect mch kn, iu khin V/f vi FCC b trt. Dng t ha ng c 0.0 (Dng ny c nhp theo % ca P0305) Dng in t ha ng c tnh theo % P0305 (dng in nh mc ng c). Vi P0320 = 0, dng t ha ng c c tnh ton s dng P0340 =1 hoc s dng P3900 = 13(kt thc qu trnh ci t nhanh), v c hin th trong thng s r0331. Ch lm mt ng c 0 (Chn ch lm mt ng c) 0. Lm mt t nhin: S dng trc g qut c gn vi ng c 1. Lm mt cng bc: S dng qut lm mt cp ngun ring 2. Lm mt t nhin v qut bn trong
P0311=...
P0320=...
P0335=...
37
n Tt Nghip
Ngnh iu Khin T ng
P0640=...
P0700=...
3. Lm mt cng bc v qut bn trong H s qu ti ng c 150% H s qu ti ca ng c tnh theo [%] tng ng vi P0305 H s ny xc nh gii hn dng in vo ln nht bng % dng in nh mc ca ng c (P0305). Bng vic s dng P0205, thng s ny c ci t ti 150% i vi momen khng i v ti 110% i vi momen thay i. Chn ngun lnh (nhp ngun lnh) 150% 0. Ci t mc nh 1. BOP (bn phm) 2. u ni 4. USS trn ng truyn BOP 5. USS trn ng truyn COM (cc u ni 29 v 30) 6. CB trn ng truyn COM (CB = mun truyn thng)
P1000=...
P1080=...
La chn im t tn s * 2 (Nhp vo ngun im t tn s) 1. im t MOP 2. im t tng t 3. Tn s c nh 4. USS trn ng truyn BOP 5. USS trn ng truyn COM 6. CB trn ng truyn COM (CB l mun truyn thng) 10. Khng c im t chnh + im t MOP 11. im t MOP + im 76t MOP 12. im t tng t + im t MOP . 76. CB trn ng truyn COM + im t tng t 2 77. im t tng t 2 + im t tng t 2 Tn s nh nht 0 Hz (Nhp tn s nh nht cho ng c, n v Hz)
38
n Tt Nghip
Ngnh iu Khin T ng
P1082=...
P1120=...
P1121=...
P1135=...
P1300=...
t tn s ng c nh nht ti ng c s chy m khng tnh n tn s im t. Gi tr c ci y c tc dng cho c quay thun v quay ngc Tn s ln nht 50.00 Hz (Nhp tn s ln nht cho ng c, n v Hz) t tn s ng c ln nht ti ng c s chy m khng tnh n tn s im t. Gi tr c ci y c tc dng cho c quay thun v quay ngc Thi gian tng tc 10.00 s (nhp thi gian tng tc, n v s) Thi gian tng tc l thi gian ng c tng tc t im dng n im c tn s ln nht(P1082) khi khng dng cch tng tc c dng ng cong. Nu thi gian tng tc c ci qu nh, iu ny c th lm xut hin cnh bo A0501 (gi tr gii hn dng) hoc lm cho b bin tn ca h truyn ng b dng vi li F0001(qu dng) Thi gian gim tc 10.00 s (nhp thi gian gim tc, n v s) Thi gian gim tc l thi gian ng c gim tc t im c tn s ln nht(P1082) n im dng khi khng dng cch gim tc c dng ng cong. Nu thi gian gimtc c ci qu nh, iu ny c th lm xut hin cnh bo A0501 (gi tr gii hn dng) hoc lm cho b bin tn ca h truyn ng b dng vi li F0001(qu dng) OFF3 thi gian gim tc 5.00 s (Nhp thi gian gim tc dng nhanh bng s) V d nhp thi gian ng c gim t tn s ln nht P1082 xung trng thi dng hn thc hin lnh OFF3 (dng nhanh) Nu t thng s thi gian gim tc qu thp th s xut hin cnh bo A0501(gi tr dng in gii hn), A0502 (gi tr in p vt qu gi tr cho php) hoc khng hot ng c do b li F0001(qu dng) hoc F0002(qu p) Mode iu khin 0 (Nhp Mode iu khin theo yu cu) 0. V/f kiu tuyn tnh 1. V/f FCC 2. V/f kiu ng Parabol 3. V/f kiu c th lp trnh c
39
n Tt Nghip
Ngnh iu Khin T ng
P1500=...
P1910=... P1960=...
P3900=...
5. V/f cho cc ng dng kiu my dt 6. V/f kiu FCC cho cc ng dng kiu my dt 19. V/f ch iu khin qua im t hiu in th c lp 20. Ch iu khin vct khng Sensor 21. Ch iu khin vct c Sensor 22. iu khin mmen xon vct khng sensor 23. iu khin mmen xon vct c sensor Chn im t mmen xon * 0 (Nhp ngun cho im t mmen xon) 0. Khng c im t chnh 2. im t kiu tng t 4. USS trn ng truyn BOP 5. USS trn ng truyn COM( cc u iu khin 29 v 30 ) 6. CB trn ng truyn COM ( CB: Mun truyn thng) 7. im t kiu tng t 2 Chn d liu cho ng c * 0 0. Khng hot ng Ti u ha thit b iu khin tc 0 0. Hm ti u ha thit b iu khin tc , phI bt ch vct iu khin vng kn (P1300=20 hoc 21). Sau khi chn xong ch ti u ha (P1960=1) th n bo A0542 khng hin th Kt thc qu trnh ci t nhanh thng s 0 ( Bt u qu trnh tnh ton ng c) 0. Khng ch ci t nhanh thng s(khng c qu trnh tnh ton Mt) 1. Ch ca nh my, nhng thng s khng c trong qu trnh ci t nhanh ( gn QC=0) 2. Qu trnh tnh ton cc thng s Mt v ci t li ch I/O theo ch nh mc 3. Ch tnh ton cc thng s Mt. Khng ci t li cc thng s khc. Ch : Vi P3900 = 1,2,3 P0340 t t ti 1 v cc d liu ph hp c tnh ton.
Kt Thc
40
n Tt Nghip
Ngnh iu Khin T ng
3.1.4. Cc tham s thng dng ca bin tn : Tham s Hin th truyn ng r0000 Hin th cc tn hiu ra c chn ca ngi dng khi c xc nh trong P0005 Trng thi truyn ng Hin th trng thi lm vic. Cc gi tr c th l: 0 Ch vn hnh (P0010 0) 1 Sn sng vn hnh 2 Li 3 Khi ng in p DC 4 ang vn hnh 5 ang dng ang gim Lu : Trng thi 3 s hin th khi np in p DC v khi bng truyn thng m rng c lp P0003 Cp truy cp ca ngi s dng. 0 Ngi s dng chn danh sch ch s 1 Mc chun : cho php truy cp cc tham s thng dng 2 M rng: Cho php truy cp n cc chc nng I/O 3 Chuyn gia: Ch dng cho cc ch chuyn gia 4 Dch v : ch dng bi nhn vin dch v ca nh sn xut P0004 B lc thng s 0 Tt c cc thng s 2 Thng s Inverter 3 Thng s ng c 4 Hin th thng s v tc 5 Thng s v lp t k thut 0 1 1 1 2 2 1 1 ngha Mc nh Mc
r0002
41
n Tt Nghip 7 Cc lnh v u I/O s 8 DAC v ADC 10 Knh im t/RFG 12 iu khin c trng 13 iu khin ng c 20 Kt ni 21 Bo li, cnh bo, gim st 22 K thut iu khin (v d nh PID) P0005 La chn thng s hin th 21 Hin th tn s 25 Hin th in p u ra 26 Hin th in p mt chiu DC 27 Hin th dng in u ra P0010 Nhm thng s a vo ci t nhanh
Ngnh iu Khin T ng
21
Vic ci t ny cho php cc thng s c lc do vy ch nhng thng s lin quan n nhm chc nng c chn 0 Bin tn sn sng 1 Ci t nhanh 30 Ci t xut xng P0100 nh tn s (Chu u/ Bc M) 0 t cng sut l KW, tn s mc nh l 50 Hz 1 t cng sut l Hp, tn s mc nh l 60 Hz 30 t cng sut l KW, tn s mc nh l 60 Hz P0300 Chn kiu ng c 1 ng c khng ng b 2 ng c ng b Ch : Thng s ny c th thay i khi P0010 = 1 P0304 in p nh mc ca ng c Di in p t 10V n 2000V
42
n Tt Nghip
Ngnh iu Khin T ng
P0305
Dng in nh mc ca ng c Di dng in t 0.12 A n 10000A
P0307
Cng sut nh mc ca ng c Di cng sut t 0.01 n 2000 [KW/Hp]
0.75
P0308
Gi tr cos ca ng c Di cos t 0 n 1
P0309
Hiu sut lm vic ca ng c Di hiu sut t 0% n 100% Thng s ny c th b thay i nu P0010 = 1 Thng s ny ch hin th khi P0100 = 1 0 2
P0310
Tn s nh mc ca ng c Di tn s t 12Hz n 650 Hz
50
P0311
Tc nh mc ca ng c Di tc t 0 (1/min) n 40000(1/min)
P0700
Chn ngun lnh 0 Ci t gi tr mc nh ca nh sn xut 1 iu khin bng BOP/AOP 2 iu khin bng cc u cc 3 Dng USS trn ng truyn BOP 2 1
P0701
Chc nng u vo s 1 0 Khng dng u vo s 1 ON/OFF1 2 Chy ngc/OFF1 3 OFF2 Dng t t 4 OFF3 Dng nhanh 9 Xc nhn li
43
n Tt Nghip 10 Chy nhp phi 11 Chy nhp tri 12 o chiu 13 Tng tn s 14 Gim tn s 15 Chn tn s c nh 1(xem P1001)
Ngnh iu Khin T ng 1 2
16 Chn tn s c nh 1+ON(xem P1001) 17 Chn tn s c nh t 1 n 7 m nh phn 25 Cho php hm DC (xem P1230 P1233) 29 Ngt ngoi 33 Khng cho php thm im t 99 Cho php tham s ha BICO Ch chuyn gia s dng P0702 Chc nng u vo s 2 0 Khng dng u vo s 1 ON/OFF1 2 Chy ngc/OFF1 3 OFF2 Dng t t 4 OFF3 Dng nhanh 9 Xc nhn li 10 Chy nhp phi 11 Chy nhp tri 12 o chiu 13 Tng tn s 14 Gim tn s 15 Chn tn s c nh 2(xem P1001) 16 Chn tn s c nh 2+ON(xem P1001) 17 Chn tn s c nh t 1 n 7 m nh phn 25 Cho php hm DC (xem P1230 P1233) 29 Ngt ngoi 33 Khng cho php thm im t 99 Cho php tham s ha BICO 12 2
44
n Tt Nghip P0703 Chc nng u vo s 3 0 Khng dng u vo s 1 ON/OFF1 2 Chy ngc/OFF1 3 OFF2 Dng t t 4 OFF3 Dng nhanh 9 Xc nhn li 10 Chy nhp phi 11 Chy nhp tri 12 o chiu 13 Tng tn s 14 Gim tn s 15 Chn tn s c nh 3(xem P1001)
Ngnh iu Khin T ng
16 Chn tn s c nh 3+ON(xem P1001) 17 Chn tn s c nh t 1 n 7 m nh phn 25 Cho php hm DC (xem P1230 P1233) 29 Ngt ngoi 33 Khng cho php thm im t 99 Cho php tham s ha BICO P0704 Chc nng u vo s 4 nh u vo tng t 0 Khng dng u vo s 1 ON/OFF1 2 Chy ngc/OFF1 3 OFF2 Dng t t 4 OFF3 Dng nhanh 9 Xc nhn li 10 Chy nhp phi 11 Chy nhp tri 12 o chiu 13 Tng tn s 14 Gim tn s 15 2
45
n Tt Nghip 15 Chn tn s c nh 4(xem P1001)
Ngnh iu Khin T ng
16 Chn tn s c nh 4+ON(xem P1001) 17 Chn tn s c nh t 1 n 7 m nh phn 25 Cho php hm DC (xem P1230 P1233) 29 Ngt ngoi 33 Khng cho php thm im t 99 Cho php tham s ha BICO P1000 La chn im t tn s 0 Khng c im t chnh 1 t bng bn phm 2 u vo tng t 3 t tn s c nh 4 USS trn ng truyn BOP 5 USS trn ng truyn COM 6 Lm vic theo CB trn ng truyn COM P1001 Tn s c nh 1 Xc nh tn s t c nh 1 1. Chn trc tip : (P0701 P0703 = 15) trong trng hp ny mi tn hiu vo tng ng vi mt tn s c nh.Nu c nhiu u vo s tc ng cng mt lc th tn s c chn l tng.Lc ny phi thm lnh ON chy bin tn. 2. Chn trc tip+lnh ON : (P0701 P0703 = 16) Chn tn s c nh kt hp vi lnh ON. Mi u vo s ng vi mt tn s c nh. Nu nhiu u vo s tc ng cng 1 lc th tn s l tng ca cc tn s c nh. 0 2 2 1
3. Chn m nh phn + Lnh ON (P0701 P0703 = 17)

Ln ti 7 tn s c nh nu dng cch ny:
46
n Tt Nghip
Ngnh iu Khin T ng
P1002
Tn s c nh 2 Xem chi tit P1001
P1003
10
P1004
15
P1005
20
P1006
25
P1007
30
P1080 P1082 P1120
Tn s t nh nht Tn s t ln nht Thi gian tng tc
0.0Hz 50.0Hz
1 1
47
n Tt Nghip
Ngnh iu Khin T ng
10s
P1121
Thi gian gim tc
10s
P3900
Kt thc ci t nhanh 0 Khng tnh ton 1 Bt u ci t nhanh. Vi Reset Factory 2 Bt u ci t nhanh Ngi s dng phi t P0010 = 0 Bng 3.4 : Cc tham s thng dng ca MM 440. 0 1
48
n Tt Nghip
Ngnh iu Khin T ng
3.2. PLC S7-200 :

3.2.1. Cu to phn cng :
PLC S7-200 l thit b iu khin logic kh trnh ca hng SIEMENS, c cu trc theo kiu modul m thnh phn chnh l cc modul CPU v cc modul m rng. Cc loi PLC S7-200 thng c phn loi theo tn ca cc modul CPU, v c cc loi thng thng l : CPU221, CPU222, CPU224, CPU224XP, CPU226.
CPU 221 Integrated DI/DO Integrated AI/AO Max.Expansion Modules Max.# of Dig.I/O channels Analogue Points I/O Max Program/Data Memory Boolean Execution Time Bit Relays/Counters/Timers 6DI/4DO 10 4KB/2KB 0.37 s 256/256/256 4 x 30 kHz High Speed Counters Real Time Clock Pulse Outputs Communication Interface Analogue Potentiometers Optional 2 x 20 kHz 1 x RS-485 1 Optional 2 x 20 kHz 1 x RS-485 1 Integrated 2 x 20 kHz 1 x RS-485 2 CPU 222 8DI/6DO 2 78 8/4/10 4KB/2KB 0.37 s 256/256/256 4 x 30 kHz CPU 224 14DI/10DO 7 168 28/14/35 8KB/12KB 0.22 s 256/256/256 6 x 30 kHz CPU 224XP 14DI/10DO 2AI/1AO 7 168 30/15/38 CPU 226 24DI/16DO 7 248 28/14/35
12KB/16KB 16KB/24KB 0.22 s 0.22 s
256/256/256 256/256/256 4 x 30 kHz 2 x200 kHz Integrated 2 x100 kHz 2 x RS-485 2 Integrated 2 x 20 kHz 2 x RS-485 2 6 x 30 kHz
Bng 3.5 : Cu to phn cng ca mt s CPU S7-200.
49
n Tt Nghip
Ngnh iu Khin T ng
Hnh 3.3 : Cu to ca CPU PLC S7-200. B nh PLC gm 3 vng chnh : 1. Vng nh chng trnh ng dng : Chia thnh 3 min : - Organisation block (OB1) : min cha chng trnh chnh. - Subrountine : min cha chng trnh con. - Interrup : min cha chng trnh ngt. 2. Vng nh tham s ca h iu hnh : Chia thnh 5 min khc nhau : - I ( Process image input ) : min nh cc u vo s. - Q ( Process image output ) : min nh cc u ra s. - M : min bin c. - T : min nh phc v Timer. - C : min nh phc v Counter. 3. Vng cha cc khi d liu : c chia lm 2 loi : DB ( Data Block ) : min cha d liu t chc thnh khi. L ( Local data block ) : min d liu a phng. Cc ch lm vic ca CPU :
50
n Tt Nghip
Ngnh iu Khin T ng
- RUN : cho php PLC thc hin chng trnh trong b nh, PLC s chuyn t RUN sang STOP nu trong my c s c hoc trong chng trn gp lnh STOP. - STOP : Cng bc PLC dng chng trnh ang chy v chuyn sang ch STOP. - TERM : cho php my lp trnh t quyt nh ch hot ng cho PLC hoc RUN hoc STOP. Cc n bo trn S7-200 : - CPU Status Led : + SF/DIAG ( n /vng ) : trng thi bo hiu h thng b li, trng thi vng bo hiu mt gi tr ang c FOCED. + RUN ( n xanh ) : ch nh PLC ang ch lm vic v thc hin chng trnh c np trong my. + STOP ( n vng ) : ch nh PLC ang ch dng chng trn - I/O Point Status Leds ( n xanh ) : Cc n bo trng thi tch cc ca cc cng vo/ra s. Cng truyn thng : S7-200 s dng cng truyn thng ni tip RS-485 vi phch ni 9 chn phc v cho vic ghp ni vi thit b lp trnh hoc vi cc trm PLC khcNgoi ra c th ghp ni S7-200 vi cc mng truyn thng khc nh cc module truyn thng m rng : EM277,EM241,
Hnh 3.4 : Cc cng truyn thng v modul truyn thng ca S7-200.
51
n Tt Nghip
Ngnh iu Khin T ng
3.2.2. Chng trnh ca PLC S7-200 :

3.2.2.1. Vng qut chng trnh : PLC hot ng theo chu k lp. Mi vng lp c gi l vng qut ( scan ). Mi vng qut c thc hin theo trnh t :
4. Chuyn d liu t b m ra ngoi vi
1. Nhp d liu t ngoi vi vo 2.Thc hin chng trnh
3. Truyn thng v t kim tra li 3.2.2.2. Cu trc chng trnh :
Cu trc ca chng trnh c th chia thnh 2 dng khc nhau : - Lp trnh tuyn tnh : ton b chng trnh nm trong 1 khi trong b nh. Khi c chn phi l khi OB1, l khi m PLC lun qut v thc hin lnh trong mi vng qut. Loi hnh cu trc tuyn tnh ny ph hp vi nhng bi ton nh, khng phc tp. - Lp trnh c cu trc : chng trnh c chia thnh nhng phn nh v mi phn c thc thi nhng nhim v chuyn bit ring ca n, tng phn ny nm trong cc khi khc nhau. PLC S7-200 c 3 loi khi c bn sau : + Khi OB1 : khi t chc v qun l chng trnh iu khin. Khi ny lun c thc thi v lun c qut trong mi vng qut. + Cc khi SBR : khi chng trnh vi nhng chc nng ring ging nh 1 chng trnh con hoc mt hm. Mt chng trnh ng dng c th c nhiu khi chng trnh con v cc khi ny c phn bit vi nhau bi tn ca n. Chng trnh con s c thc hin khi c gi t chng trnh chnh. + Cc khi INT : l loi khi chng trnh c bit c kh nng trao i mt lng d liu ln vi cc khi chng trnh khc. Chng trnh ny s c thc hin mi khi c s kin ngt tng ng xy ra.
3.2.3. Phn mm STEP7 MICROWIN :

Chng trnh ca S7-200 c th c vit theo 3 dng : LAD, STL, FBD. i cng l tp lnh, bao gm cc lnh x l bit, cc lnh ton hc, cc lnh v Timer, cc lnh v Counter,
52
n Tt Nghip
Ngnh iu Khin T ng
Cng c son tho chng trnh ca S7-200 l phn mm STEP7MicroWIN. Ta c th s dng cng c ny Download chng trnh t my tnh xung PLC cng nh Upload chng trnh t PLC ln my tnh theo di v chnh sa. 3.2.3.1. Giao din phn mm : Step7-MicroWin l mt phn mm ca hng SIEMENS cung cp nh mt cng c son tho chng trnh S7-200, chy trn nn Windows 32bit, tri qua nhiu phin bn khc nhau. Ngoi vic phc v lp trnh cho PLC S7-200, phn mm ny cn c rt nhiu cc tnh nng khc nh cc cng c g ri, kim tra li, h tr nhiu cch lp trnh vi cc ngn ng khc nhau Phn mm ny cng c xy dng mt phn tr gip (Help) c th ni l rt y , chi tit v tin dng. Ngi dng c th tra cu cc vn v PLC S7-200 mt cch rt nhanh chng, r rng v d hiu.
M, to mi, lu mt CT iu khin Down load/Upload Cng c kt ni cc lnh Nt thay i trng thi lm vic ca PLC Nt kim tra trng thi ca chng trnh.
Cc khi chc nng

Vng son tho chng trnh
Cc khi hm, lnh
Hnh 3.5 : Giao din ca phn mm STEP7-MICROWIN.
53
n Tt Nghip 3.2.3.2. Mt s thnh phn quan trng : - Program Block:
Ngnh iu Khin T ng
Khi click chut vo nt ny ta s tr v c vng son tho chng trnh. vng ny ta c th thm bt cc u vo/ra, cc bin, cc lnh, hm thc hin chng trnh iu khin. - Communications : y ta c th thay i cch m my tnh truyn thng vi PLC S7200 (PPI, MPI, tc truyn) hoc kim tra c hay khng s truyn thng gia my tnh v PLC S7-200 (kim tra s c mt ca PLC hay khng). - Symbol Table: Click chut vo y, ta s c mt bng m ta c th nh ngha cc tn bin v t a ch tng ng cho cc bin c th d nh v d kim tra. Cc bin ny c th l cc u vo/ra, cc bin trung gian - Instructions : y l mt trong nhng thnh phn quan trng nht ca STEP7- MicroWIN. N bao gm ton b cc lnh v khi hm ca STEP7- Micro WIN c th to c mt chng trnh iu khin cho PLC S7-200. Ngi dng c th tm thy cc lnh hoc hm mnh cn da trn cc nhm c cng chc nng m STEP7- MicroWIN phn loi sn. Trong thng dng nht l cc khi: + Bit Logic : bao gm cc lnh lm vic vi bit v thc hin cc php ton logic nh AND, OR, NOT, SET, RESET + Compare : bao gm cc khi lnh dng so snh d liu kiu Byte, Integer, Double Integer, Real, String nh >, <, =, , ... + Convert : cc lnh dng chuyn i qua li cc kiu d liu : t Byte -> Integer, Integer -> Double Integer,... + Interger Math, Floating-Point Math: nhm lnh lm vic vi s nguyn 16bit, 32bit v s thc. Nhm lnh ny thc hin cc php ton s hc nh +, -, ,
54
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Ngnh iu Khin T ng
+ Move : cc khi lnh dng di chuyn d liu t vng nh ny sang vng nh khc ca PLC. + Timer : y l khi lnh lm vic vi cc loi timer ca S7-200. + Counter : y l khi lnh lm vic vi cc loi counter ca S7-200. Ngoi ra cn cc khi khc cng rt quan trng chng ta c th tham kho thm phn Help ca STEP7- MicroWIN. c th bit cch s dng cng nh cch thc mt khi hm hoc lnh lm vic nh th no, chng ta chn khi hm, lnh v nhn F1 tham kho phn Help ca phn mm. - Vng son tho : y l vng m STEP7- MicroWIN dnh cho ngi dng son tho cc chng trnh iu khin ca ring mnh. y ngi dng c th thm cc lnh cc khi hm, cc cu trc iu khin chng trnh to cc kt ni gia cc cu lnh thc thi cc nhim v iu khin. C 3 phng php hay ni cch khc l 3 ngn ng khc nhau vit mt chng trnh iu khin cho PLC S7-200: + Statement List (STL): lp trnh dng danh sch lnh da trn cc t gi nh. + Lader (LAD): lp trnh dng hnh thang c dng nh mt s nguyn l mch. + Function Data Block (FDB): lp trnh da trn cc khi logic c bn AND, OR Cng nn lu s khc nhau gia vng son tho khi dng ngn ng LAD so vi cc ngn ng khc.Ngi dng c th thc hin vic chuyn i vic lp trnh gia cc ngn ng khc nhau thng qua vic la chn ngn ng lp trnh khi vo menu : View STL hoc LAD hoc FDB. Ngoi ra khi son tho chng trnh STEP7- MicroWIN cng h tr ngi dng vi cc thng bo li v c php, v d liu
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3.3. Phn mm WINCC 6.0 :

3.3.1. Tng quan v WinCC :
WinCC (Window Control Center) l mt h thng phn mm iu khin gim st cng nghip, c tnh k thut v h thng mn hnh hin th ha iu khin cc nhim v t ra trong sn xut v t ng ha qu trnh. H thng ny c cha nhng module chc nng tch hp cng nghip cho hin th ha, thng bo, lu tr v cc bo co. N l mt trnh iu khin mnh, nhanh chng cp nht cc hnh nh ca cc qu trnh quan st, v cc chc nng lu tr an ton bo m mt tnh li ch cao. WinCC cn c cc giao din m cho cc gii php ca ngi dng. Nhng giao din ny c th tch hp trong nhng gii php t ng ha phc tp, cc gii php cho h thng m. S truy nhp ti ni lu tr d liu tch hp bi cc giao din chun ODBC v SQL. S lng ghp nhng i tng v cc vn bn c tch hp bi OLE2.0 v OLE Custom Controls (OCX). Nhng c ch ny lm cho WinCC l mt i tc d hiu, d truyn ti trong mi trng Windows. WinCC h tr cho tt c cc loi my tnh, n tch hp vi tt c cc loi my tnh c nhn PC. Yu cu cu hnh my tnh c trong bng di y : Ti thiu CPU RAM Graphics Controller Resolution Hard Disk PentumII 266MHz 96MB SVGA (4MB) 800*600 500MB trng CD-ROM Drive Khuyn co PentumII 400MHz 128MB XGA (8MB) 1024*768 >500MB trng CD-ROM Drive
Bng 3.6 : Yu cu cu hnh my tnh cho WinCC.
3.3.2. Cu hnh WinCC V6.0 :

3.3.2.1. Cc loi Project :
Client : c gn c nh cho mt server trong multi-user project. Client c th

c s dng trong multi-user project hoc trong mt h thng phn tn.
Multi-client : i vi WinCC V6.0, mt multi-client c th truy nhp ti a 6

server.
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Server: server ca mt multi-user project vi client v cc multi-client. Mt i redundant server dng d phng s c c th nh mt server. 3.3.2.2. WinCC Explorer : 3.3.2.2.1. V tr ca WinCC Explorer trong WinCC : N c xut hin khi khi ng WinCC. Tt c cc phn ca WinCC u c khi ng t y. T ca s WinCC Explorer bn c th truy nhp vo tt c cc thnh phn m mt project giao din ngi my cn c cng nh vic xy dng cu hnh cho cc thnh phn ring r . WinCC Explorer cung cp cc thng tin v cc mc di y:
Chc nng ca WinCC Explorer. Kin trc ca WinCC Explorer. Cc Editer chun.
3.3.2.2.2. Chc nng ca WinCC Explorer : WinCC Explorer gm tt c cc chc nng qun l h thng ca WinCC. Ti y ta c th t cu hnh (Computer, Tag) v khi ng mode Run-time. Nhim v ca b qun l d liu (Data Manager) : y l mt phn ca WinCC Explorer, n cung cp cc hnh nh qu trnh, b m cho cc tag. Nhim v ca WinCC Explorer :
To mt project mi. t cu hnh trn vn. Gi v lu tr project. Qun l project: m, lu, di chuyn v copy. Chc nng n bn mng cho nhiu ngi s dng (Client-Server
Inviroment).
Trnh by (th hin) cu hnh d liu. iu khin v t cu hnh cp bc cho cc picture / kin trc h thng,
chng hn nh bng cch th hin cy th mc.
Ci t thng s tng th nh ngn ng, h thng / ng dn ngi dng. t cu hnh cho v tr cc chc nng c bit ca ngi dng. 57
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Lu tr cc ti liu phn hi (feedback documentation). Lp bo co trng thi ca h thng. Chuyn i gia chy thc v t cu hnh. Th cc module nh m phng khi chy (simulation), tr gip hot ng
t cu hnh d liu, chuyn i cc picture, th hin trng thi v to thng bo.
Qun l d liu: cung cp cc hnh nh qu trnh (b m) vi cc gi tr

ca tag theo nhng cch sau y :
- Theo chu k. - Chu k vi s thay i.

3.3.2.3. Cc thnh phn c bn trong mt project ca WinCC : Mt project ca WinCC cha 3 thnh phn chnh :
Computer : Qun l tt c cc trm vn hnh (WorkStation) v trm ch

(Server) nm trong project.
Tag Managerment : L khu vc qun l tt c cc knh, cc quan h logic,

cc bin ni (Internal tag), bin ngoi (External tag), bin qu trnh (tag process) v cc nhm tag (tag groups).
Data type : Cha cc loi d liu c gn cho cc tag v cc knh khc

nhau. 3.3.2.4. Cc trnh son tho :
H thng ha (Graphics Designer) : L mt trnh son tho ha cung cp

cc i tng ha v cc bng mu cho php to cc hnh nh qu trnh t n gin n phc tp. Nhng c tnh ng c th c to ra cho tng i tng ha ring l. Cc i tng ha c th do ngi s dng to ra hoc ly trc tip trong th vin ca WinCC.
n bn cc Action (Global Script) : Cho php to ra nhng hnh ng cho cc

i tng. Trnh son tho ny cho php to ra cc hm ging nh trong C hoc VB. Cc hnh ng ny c th s dng trong mt hoc nhiu project ty thuc vo m code c to ra.
H thng thng bo (Alarm Logging) : Cho php thao tc la chn vic thu
thp v lu tr cc kt qu ca qu trnh v chun b hin th cc thng bo.
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C th la chn cc khi thng bo (Message blocks), cc lp thng bo (Message classes), loi thng bo (Message type) hin th cc thng bo v bo co.
Lu tr cc gi tr o ca qu trnh (Tag Logging) : c s dng thu thp

d liu t cc qu trnh v chun b chng cho vic hin th v lu tr. D liu c nh dng cho vic lu tr, thi gian thu thp v lu tr c th c la chn trc.
H thng bo co (Report Designer) : L mt h thng tch hp cc bo co

cung cp ti liu theo thi gian nh trc hoc theo s kin iu khin ca cc thng bo, cc thao tc, cc ni dung lu tr, cc d liu hin thi hoc d liu lu tr trong cc dng bo co ca ngi s dng hoc c th la chn cc dng layout trong project. N cung cp y cc giao din cho ngi s dng vi cc cng c ha v a ra cc kiu bo co khc nhau.
Text Library : Cho php son tho cc vn bn s dng trong qu trnh chy
thc bi cc module khc nhau. 3.3.2.5. Tag v Tag Groups : Trong phn mm WinCC c mt khi nim c bit quan trng cn phi nm vng khi xy dng mt h thng iu khin gim st l khi nim v Tag v Tag Groups. Tag thc ra l mt thnh phn trung gian cho vic truy nhp cc gi tr qu trnh. Trong mt project th Tag ch mang mt tn duy nht v mt loi d liu duy nht. Cc Tag ny c gn bi cc mi quan h logic, cc mi lin h c nh r bi knh phn phi cc gi tr qu trnh ti cc Tag s dng ti cc im ni. WinCC Tags cha trong mt c s d liu ca mt project rng. Sau khi chy WinCC th tt c cc Tag u c ti vo v tng ng vi cu trc Runtime c dng ln. Tag Groups c dng t chc cc Tag thnh cc cu trc. Tt c cc Tag u c th c t chc trong cc nhm Tag nhm lm tng s r rng ca project. WinCC Tags m t mt dng d liu thnh phn duy nht trong mt project v nhng lut cho php truy cp d liu ny. Ni chung, d liu qun l phn bit hai loi Tag :
Internal Tag (Tag trong) : L cc khi nh trong WinCC c phn chia theo
chc nng nh mt PLC thc. Chng c th c tnh ton v chnh sa trong WinCC v khng c a ch trn lp PLC.
External Tag (Tag ngoi) : Gn cc a ch v kt ni trong cc lp PLC. Trong

loi Tag ny c mt khung c bit c gi l Tag d liu th (Raw Data Tag-RDT). T mt quan im chung, d liu th ph hp vi mt dng khung d liu thng bo trn mc vn chuyn. RDT khng hin th c trong Graphics Designer, chng ch
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c s dng trong cc ng dng khc ca WinCC nh: Tag Logging v Global Scrips. Trong Driver truyn thng SIMATIC S7 Protocol Suite c 4 loi RDT :
RDT-EVENT: Event Processing. RDT-ARCHIV: Active Data Connection. RDT-BSEND: Sending/Receiving a data block. RDT-S7PDV: Transparent communication. 3.3.3. Gii thiu mt s trnh son tho v i tng chun ca WinCC :
3.3.3.1. Thit k ha ca WinCC (Graphics Designer) : 3.3.3.1.1. Chc nng ca Graphics Designer : c s dng to ra hnh nh ca qu trnh. N c c im sau :
D s dng, giao din n gin vi cng c v cc bng mu ha. Cu hnh sp xp hp l vi cc th vin icon v cc i tng tch hp. M ra giao din cho cc ha quan trng v cung cp giao din OLE 2.0. Hnh vi ng ca cc i tng nh c th cu hnh c vi h tr t mt trnh tr gip (Dynamic Wizard). Cc lin kt ti cc chc nng ph nh cu hnh script mnh. Cc lin kt ti cc i tng ha m ngi s dng c th to ra .
3.3.3.1.2. Cu trc ca Graphics Designer :
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Ngnh iu Khin T ng Hnh 3.6 : Cu trc ca Graphics Designer.
Graphics Designer cha cc mc sau:
1.
Cc bng v thanh cng c phc v cho thao tc vi Graphics Designer :
Menu Bar. Palette chun. Thanh trng thi. Thanh lp. 2.

Cc Palette to v sa cc i tng ha :
Palette mu. Palette i tng.

Palette kiu.
Palette v sp xp. Palette v phng to, thu nh hnh. Palette font. 3.

Bng i tng :
Cc i tng chun (Standard Object) : Ti y c rt nhiu i tng,

s dng v ly chng th ch cn nhp chut v ko chng vo ca s lm vic. C th dng chut ko thay i kch thc ca i tng. Cc i tng y gm : ng thng, hnh a gic, ng gp khc, Elip, ng trn, hnh ch nht
Cc i tng thng minh (Smart Object) : Gm cc i tng nhng : - ng dng Window (Application Window) : L nhng i tng thng
bo h thng (Alarm Logging), lu tr h thng (Tag Logging), bo co h thng (Print jobs). Application Window m ra nhng ca s ng dng v qun l n hin th v vn hnh.
- iu khin nhng v lin kt i tng (OLE control) : S dng OLE

control cung cp cc cng c Window (nt bm, hp la chn). Cc thuc tnh ca n c biu th trong ca s Object Properties v tab Event.
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- Trng vo/ra (I/O Field) : S dng nh mt trng vo hoc ra hoc

c vo ln ra. Cc dng d liu cho php s dng vi I/O Field:
Nh phn (Binary). H 16 (Hexadecimal). H thp phn (Decimal). Xu k t (String). - Bar : Thuc tnh ca n nh hng n s xut hin v tnh nng ca
n. N th hin cc gi tr bng th c quan h vi gii hn cao, thp hoc hon ton ch l miu t bng ha phi hp th hin nhng gi tr vi t l do ngi s dng nh trc.
- Hin th trng thi (Status Display) : S dng th hin bt k con s

ca nhng trng thi khc nhau no. Cho php thc hin hin th ng bng cch ni n vi gi tr ca tt c cc Tag tng ng vi nhng trng thi khc nhau.
- Danh sch vn bn (Text List) : S dng Text List a gi tr cho

vn bn. N c th s dng nh mt danh sch vo (vo l danh sch, ra l gi tr) hoc danh sch ra (vo l gi tr, ra l danh sch) hoc phi hp danh sch/vn bn. Dng s liu l thp phn, nh phn hoc bit d liu u c th s dng
Cc i tng ca Window (Window Object) : - Nt bm (Button) : S dng iu khin s kin qu trnh. N c hai
trng thi n xung v khng n. Lin kt ti qu trnh bng cch thc hin cc thuc tnh ng tng ng.
- Hp th (Check-Box) : N c s dng khi m c nhiu s la chn

bng cch kch ln tng trng hp m ngi s dng cn. Cho php lin kt mm do vi qu trnh bng cch thc hin nhng thuc tnh ng tng ng.
- Nhm la chn (Option Group) : Tng t nh Check-Box nhng

y l la chn n.
- Nt trn (Round Button) : L mt cng c ging nh Button phc v

cho vn hnh s kin qu trnh
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- Slider : L cng c in hnh chuyn ng phc v cho iu khin qu

trnh. Phm vi iu khin nm gia gi tr nh nht v gi tr ln nht. C th thit lp mt s kin ti qu trnh bng cch thc hin nhng thuc tnh ng tng ng. 3.3.3.2. Tag Logging : 3.3.3.2.1. c im : Tag Logging cha cc hm ly d liu t cc qu trnh thc hin v chun b d liu hin th v lu tr. N c th mang li ngha cng ngh v k thut lin quan ti trng thi vn hnh h thng. c im :
- n gin ha vic pht hin sm nguy him v cc iu kin gy ra li. - Sng sa, d hiu trong th tc vn hnh. - Gip tng nng sut. - Gip ci tin cht lng sn phm. - Hiu qu v ti u trong vic s dng h thng. - To vn bn cho tin trnh ca cc gi tr qu trnh.
Tag Logging c chia thnh 2 thnh phn :
Cu hnh h thng (Tag Logging Configuration System/Tag Logging CS) : Tt

c cc c tnh cn thit cho lu tr v hin th u c gn d liu bng Tag Logging Configuration System. Nhng c tnh ny phi c to ra v chun b trc khi khi ng chy thc h thng
Chy thc h thng (Tag Logging Runtime/Tag Logging RT) : Chp nhn d
liu t v lin kt chng vi nhng c tnh c ch nh v chun b cho lu tr v hin th. 3.3.3.2.2. Cc thnh phn ca Tag Logging : Tag Logging c 2 thnh phn chnh : Timer v Archive. 3.3.3.2.3. B nh thi Timer : Tag Logging gii thiu 2 loi h thng Timer khc nhau : Timer thu nhn: L khong thi gian m cc gi tr c Tag Logging copy t hnh nh qu trnh ca b qun l d liu (Data Manager).
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Timer lu tr: L khong thi gian m d liu c np vo vng lu tr. B nh thi lu tr lun lun l mt s nguyn ln b nh thi thu nhn c thit lp. 3.3.3.2.4. B phn lu tr (Archive) : Th mc lu tr c cha thng s mc nh cho vic to ra mt b phn lu tr v xc nh cc Tag lin quan trong sut mi lin h gia chng vi qun l d liu ca Tag. To ra mt n bn hay nhiu lu tr c thc hin trong vng t cu hnh Archive. Ti mt thi im mt lu tr mi cng c np vo project. Trong WinCC cho php s dng 3 dng lu tr: Lu tr d liu qu trnh (Process Value Archive). Lu tr dng nn (Compressed Archive). Lu tr ca ngi s dng (User Archive). Lu tr d liu qu trnh : Cc gi tr ca qu trnh c thu nhn v mi trng WinCC x l tnh ton thng qua cc mi lin h logic l cc Tag qu trnh. Mi mt thnh phn lu tr nhn cc Tag ca qun l d liu. Mi lin kt gia gi tr qu trnh v lu tr c hnh thnh khi lu tr m ngi s dng to ra c ni vi mt Tag. Lu tr dng nn : Lu tr dng ny nn d liu v phi hp vi cc s liu mt cch hiu qu. Theo cch ny cc gi tr o c th c thu thp trc tip v c sao chp ngay sau . Loi lu tr ny cho php lu tr lu di tt c cc kiu Tag khc nhau m Tag Logging s dng. Lu tr ca ngi s dng : Bt k s lng Tag do ngi s dng to ra u c np vo trong User Archive. V l do m ngi dng c th a vo phng php lm vic hay phng php thay i no sau np chng vo trong User Archive v nu cn thit th thng qua chng lin kt vi PLC. Ngoi ra lu tr ca ngi dng cn c s dng thu nhn charge data (l tng hp ca cc thng bo, d liu qu trnh v cc gi tr t cho mi phn sn phm) Loi lu tr ny c t chc thnh cc bng ring r trong c s d liu tr ct u tin ca bng (c kin trc hon ton t do). Mi lu tr ca ngi dng phi co mt tn ring bit. Truyn thng gia PLC v WinCC c thc hin do cu trc bc in ph hp vi quy c r rng theo kin trc ca chng.
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Ngnh iu Khin T ng
Report Designer l mt phn mm c bn ca WinCC n cung cp cc chc nng cho vic o to v in cc bo co. WinCC cung cp hai trnh son tho cho vic to bo co : - Trnh son tho to cc bo co theo trang(Page layout). - Trnh son tho to cc bo co theo dng (Line layout). WinCC cung cp nhng hp thoi cho php la chn cu hnh ca d liu c in ra trong bo co. Nhng hp thoi ny c sp xp theo nhng ng dng ca chng :
Scripts trong Graphics Designer. Alarm Logging CS. Alarm Logging Runtime. Win CC Explorer. Global Scripts. Tag Logging CS. Tag Logging RunTime. Text Library. User Administrator.
S dng nhng i tng ng (Dynamic Oject) ca Report Designer to d liu cho bo co. Nhng i tng ng ny phi c lin kt vi cc ng dng thch hp. Trong khi in bo co nhng i tng ng c cung cp nhng gi tr hin thi. i vi vic in bo co, bn phi t thi gian in, v mi trng in, h thng cung cp cc la chn c th sau :
In c khi ng bi ngi s dng (Print start by user). Ti mt im c chn trc (At a preselected time). Chu k in (Cyclic output). In ra mn hnh (Output to the screen). In ra mt my in c chn trc (Output to a preselected printer). 65
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In vo mt file (Output to a file). Output to a page area.

3.3.3.3.2. Cc bo co : Trong WinCC, bn c th s dng cc bo co cho cu hnh d liu ca bn (ti nguyn ca d n) v bo co trc tip d liu trong cc ng dng chy.Cu trc v hnh dng ca cc bo co ny phi chnh xc.Report Designer phn bit mt s bo co theo cch trnh by v ni dung d liu ca chng. Cch trnh by ca bo co c phn loi nh sau :
- Theo trang (Page layout). - Theo dng (Line layout).

Trong Page layout, Report Designer cung cp cho bn nhng i tng tnh (static) i tng ng (dynamic) v cc i tng h thng to mt cu trc trc quan. Bo co cc ti nguyn ca project (Project documentation) :
D liu t Alarm Logging. D liu t WinCC Explorer. D liu t Global Scripts. D liu t Tag Logging. Text Library. User Administrator.
Theo cc bo co c sn trong khi chy thc mt s ng dng :
Message sequence report. Message archive report. Achirve report.

3.3.3.4. Trnh son tho Alarm-Logging : 3.3.3.4.1. Chc nng : B son tho Alarm Logging chu trch nhim nhn v lu tr cc thng bo (message). N c cc chc nng nhn cc thng bo t cc qu trnh, v chun b, hin th, chp nhn v lu tr chng. Alarm Logging c th :
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- Cung cp thng tin y thng tin chnh xc v li v trng thi hot ng. - c dng pht hin sm cc trng hp nghim trng. - Trnh v gim bt thi gian cht (downtime). - Tng cht lng. - Cung cp ti liu nh hng cho cc li v trng thi hot ng. H thng thng bo x l kt qu t cc chc nng theo di cc tc v trong qu trnh, mc t ng v trong cc h thng WinCC. Cc s kin cng c lu tr in t v trn giy. Cc thng bo c th c truy nhp ring bit. Thng tin b sung vi cc thng tin ring m bo phn lp v sa li nhanh chng. 3.3.3.4.2. Phn loi : Alarm Logging c chia thnh 2 phn : H thng cu hnh v h thng thi gian thc. 1. Nhim v ca h thng cu hnh Alarm Logging (ALGCS) : s dng h thng cu hnh Alarm Logging (ALGCS) to cu hnh cc thng bo sao cho chng t c h thng trong thi gian thc m bn mong mun. Cu hnh h thng thng bo c th n gin ha nh s dng wizard : - Winzard h thng cung cp h tr khi thit lp h thng thng bo c bn. - Winzard lin kt n gin ha vic gn cc Tag qu trnh cho thng bo. - Hn na, cc hp thoi cu hnh khc nhau c sn s cho php x l ng thi nhiu thng bo. 2. Nhim v ca h thng thi gian thc Alarm Logging (ALGRT): nhn thng bo v chp nhn li bo nhn. N chun b thng bo hin th v lu tr.
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Chng IV : GHP NI GIA PC, PLC V BIN TN

4.1. Giao din truyn thng OPC :
Tin b ca cc h thng bus trng cng vi s ph bin ca cc thit b cn trng thng minh l hai yu t quyt nh ti s chuyn hng sang cu trc phn tn trong cc gii php t ng ha. S phn tn ha ny mt mt mang li nhiu u th so vi cu trc x l thng tin tp trung c in, nh tin cy v tnh linh hot ca h thng, nhng mt khc cng to ra hng lot thch thc mi cho gii sn xut cng nh cho ngi s dng. Mt trong nhng vn thng gp phi l vic tch hp h thng. Tch hp theo chiu ngang i hi kh nng tng tc gia cc thit b t ng ha ca nhiu nh sn xut khc nhau. Bn cnh , tch hp theo chiu dc i hi kh nng kt ni gia cc ng dng c s nh o lng, iu khin vi cc ng dng cao cp hn nh iu khin gim st v thu thp d liu (supervisory control and data acquisition, SCADA), giao din ngi-my (human-machine interface, HMI) v h thng iu hnh sn xut (manufactoring execution system, MES). Vic s dng mt chun giao din v vy tr thnh mt iu kin tin quyt. Tiu biu cho hng i ny l chun OPC, c chp nhn rng ri trong cc ng dng t ng ha qu trnh cng nghip.
4.1.1. Tng quan v kin trc OPC :

OPC (OLE for Process Control) l mt chun giao din c hip hi OPC Foundation xy dng v pht trin. Da trn m hnh i tng thnh phn (D)COM ca hng Microsoft, OPC nh ngha thm mt s giao din cho khai thc d liu t cc qu trnh k thut, to c s cho vic xy dng cc ng dng iu khin phn tn m khng b ph thuc vo mng cng nghip c th. Trong thi im hin nay, OPC cng nh COM tuy mi c thc hin trn nn Windows, song c nhiu c gng ph bin sang cc h iu hnh thng dng khc. Vi mc ch ban u l thay th cho cc dng phn mm kt ni nh I/O-Drivers v DDE, OPC qui nh mt s giao din chun cho cc chc nng nh : Khai thc, truy nhp d liu qu trnh (Data Access) t nhiu ngun khc nhau (PLC, cc thit b trng, bus trng, c s d liu,..). X l s kin v s c (Event and Alarm). Truy nhp d liu qu kh (Historical Access). Trong tng lai OPC s h tr cc chc nng khc nh an hon h thng (Security) v iu khin m (Batch). OPC s dng c ch COM/COM cung cp cc dch v
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truyn thng cho tt c cc ng dng h tr COM. C th k ra hng lot cc u im ca vic s dng OPC nh : Cho php cc ng dng khai thc, truy nhp d liu theo mt cch n gin, thng nht. H tr truy nhp d liu theo c ch hi tun t (polling) hoc theo s kin (event-driven). c ti u cho vic s dng trong mng cng nghip. Kin trc khng ph thuc vo nh cung cp thit b. Linh hot v hiu sut cao. S dng c t hu ht cc cng c phn mm SCADA thng dng, hoc bng mt ngn ng bc cao (C++, Visual Basic, Delphi,..). Ct li ca OPC l mt chng trnh phn mm phc v gi l OPC-Server, trong cha cc mc d liu (OPC-Item) c t chc thnh cc nhm (OPC-Group). Thng thng, mt OPC-Server i din mt thit b thu thp d liu nh PLC, RTU, I/O hoc mt cu hnh mng truyn thng. Cc OPC-Items s i din cho cc bin qu trnh, cc tham s iu khin, v.v... OPC c xy dng da trn tng ng dng cng ngh COM nhm n gin ha, chun ha vic khai thc d liu t cc thit b cn trng v thit b iu khin, tng t nh vic khai thc mt h thng c s d liu thng thng. Ging nh COM, OPC khng qui nh vic thc hin khai thc c th, m ch nh ngha mt s giao din chun. Thay cho vic dng C/C++ dng nh ngha mt giao din lp trnh nh thng thng, ngn ng dng y (gi l interface definition language hay IDL) khng ph thuc vo nn ci t hay ngn ng lp trnh.
Hnh 4.1 : Kin trc s lc ca OPC. Nh c minh ha trn Hnh 4.1, hai kiu i tng thnh phn quan trng nht trong kin trc OPC l OPC-Server v OPC-Group. Trong khi OPC-Server c nhim
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v qun l ton b vic s dng v khai thc cc d liu, th cc i tng OPC-Group c chc nng t chc cc phn t d liu (items) thnh tng nhm tin cho vic truy nhp. Thng thng, mi item ng vi mt bin trong mt qu trnh k thut hay trong mt thit b iu khin.
4.1.2. OPC Server :

OPC Server l mt i tng phn tn, cung cp giao din OPC chun cho cc ng dng. Vic giao tip qua cc mng cng nghip c thc hin bng cc li gi n gin, thng nht khng ph thuc vo mng hai phng php truy cp d truyn thng v giao thc c s dng. OPC Server h tr liu :
Polling : Client ch ng yu cu Server cung cp d liu mi khi cn. Publisher/Subscriber : Client ch cn mt ln yu cu Server, sau ty theo cch t (Theo chu k, theo s thay i ca gi liu hoc theo mt s kin no ). Phng php ny cn c gi l truy cp khng ng b.
Hnh 4.2 : Kin trc Client/Server trong OPC. Chun OPC hin nay qui nh hai kiu giao din l Custom Interfaces (OPC Taskforce, 1998b) v Automation Interface (OPC Taskforce, 1998c). Kiu th nht bao gm mt s giao din theo m hnh COM thun ty, cn kiu th hai da trn cng ngh m rng OLE-Automation. S khc nhau gia hai kiu giao din ny khng nhng nm m hnh i tng, cc ngn ng lp trnh h tr m cng cn tnh nng, hiu sut s dng. Custom Interface dng cc ngn ng nh C/C++phc tp hn nhng hiu sut cao, da trc tip trn cc i tng COM. Automation Interface dng cc ngn ng n gin, phong php lp trnh n gin, hiu qu thp, da trn cng ngh COM automation.
4.2. iu khin bin tn thng qua giao thc USS :

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4.2.1. Giao thc USS (USS protocol) :

Giao thc USS (Universal Serial Interface Protocol) nh ra mt k thut truy cp theo nguyn tc ch-t (Master-Slave) cho vic truyn thng trn bus ni tip. Theo , mt trm ch c th truyn thng vi ti a 31 trm t kt ni trn ng bus. Trm ch qun l cc trm t thng qua cc bc in (telegram). Mt trm t s c la chn bi trm ch thng qua a ch c trong bc in. Mt trm t s khng th t chuyn i nu khng c yu cu, v vic truyn trc tip cc gi tin gia cc trm t khng th xy ra. Cu trc ca bc in :
Mt bc in c bt u bi k t (character) STX, sau l di bc in LGE v byte a ch ADR. Tip theo l phn d liu ca ngi s dng. Bc in kt thc bi mt k t kim tra khi BCC. 1. STX ( Start of Tex ) : STX l mt byte k t ASCII (= 02 hex) c s dng ch th bt u ca mt gi tin. 2. LGE ( Telegram Length ) : LGE l mt byte ch ra s lng byte c trong gi tin. Ty theo tng USS c th m di ca bc in c th thay i, v di ca n phi c ch r byte th 2 ca bc in (LGE). Ty thuc vo cu hnh, cc bc in c di c nh c th c nh r. Cc bc in c di khc nhau c th c s dng cho cc trm t khc nhau trn bus. Tng chiu di ti a ca mt bc in l 256 bytes. LGE c ch r bi d liu ngi s dng, byte a ch ADR v k t kim tra BCC. di thc t ca bc in s ln hn di trong LGE l 2 byte bi byte STX v byte LGE khng c m trong LGE. 3. ADR ( Address byte ) : ADR l mt byte n cha a ch ca trm t. Cu trc ca 1 byte ADR:
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a ch ca trm t (t 0 n 3) c cha trong 5 bit thp ca ADR (bit 0 n bit 4). Bit 5 l bit truyn thng (broadcast bit). Nu n c set ln 1 th gi tin l gi tin truyn thng v c thc hin cho tt c trm t. Bit 6 ch th mt mirror telegram. S lng nt c nh gi v a ch trm t c a li v trm ch. Bit 7 khng c s dng v c set bng 0. 4. BCC (Block Check) : BBC l mt byte cheksum s dng kim tra tnh hp l ca gi tin. 5. D liu ngi s dng ( Useful Data Characters ) : Phn dnh cho d liu ca ngi s dng c chia ra lm 2 vng l vng ID v gi tr ca tham s PKW (parameter ID value) v vng d liu qu trnh PZD (process data) :
Gi tr ca PKW v PZD cho bit ni dung iu khin ca trm ch ti trm t c la chn.
4.2.2. Kt ni gia PLC v bin tn :

SIEMENS cung cp cho ngi s dng mt giao thc ghp ni gia PLC v bin tn qua cng truyn thng RS485 l USS protocol v th vin lp trnh cho giao thc l USS_protocol library. Th vin ny ch s dng cho h SIMATIC S7-200 vi cc yu cu v CPU : - B nh ti thiu l 3000 bytes. - Giao thc ch lm vic cng truyn thng Port 0 ca PLC ch free port.
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- Vng nh V (Variable memory ) c ti thiu 400 bytes v mt b m 16 bytes cho mt s lnh c v ghi thng s bin tn. Do ch c cc PLC S7-200 loi CPU 224 tr ln mi s dng c th vin ny. 4.2.2.1. S ni dy : (nh hnh v ) Chn 3 ca PORT 0 ni vi chn 29 ca bin tn. Chn 8 ca PORT 0 ni vi chn 30 ca bin tn.
Hnh 4.3 : S u ni dy gia PLC v bin tn. 4.2.2.2. Ci t tham s bin tn : S dng Keypad trn bin tn thit lp cc tham s : 1. Reset bin tn v trng thi ban u : P0010 = 30 P0970 = 1. Nu b qua bc ny, phi chc chn rng tham s c t theo gi tr sau : USS PZD length : USS PKW length : P0003 = 3 P2012 index 0 = 2. P2013 index 0 = 127.
2. Bt ch truy nhp Read/write vi tt c cc tham s ( ch chuyn gia) 3. Kim tra trng thi motor :
P0304 : in p nh mc motor (V) P0305 : dng in nh mc motor (V) P0307 : cng sut nh mc motor (V) P0310 : tn s nh mc motor (V) P0311 : tc nh mc motor (V)
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Nhng thay i c th dao ng thy theo loi motor c dng. Khi ci t tham s bng lnh P0304, P0305, P0307, P0310, P0311 trc tin phi t P010 bng 1. Khi kt thc ci t set P010 v 0 v P0304, P0305, P0307, P0310, P0311 ch c thay i trong ch y nhim nhanh (quick commissioning mode).
4. t kiu iu khin (Local/Remote) : P0070 index 0 = 5 5. t tn s t cho USS 6. Ramp up time 7. Ramp down time 8. t chun tn s ni tip 9. t ch bnh thng USS
: P1000 index 0 = 5 : P1120 = 0 650.00 : P1121 = 0 650.00 : P2000 = 1 650Hz : P2009 index 0 = 0
10. t tc Baud cho giao din ni tip RS-485 :

P2010 index 0 = 3 4 5 6 7 8 9 12 (1200 baud) (2400 baud) (4800 baud) (9600 baud) (19200 baud) (38400 baud) (57600 baud) (115200 baud)
11. Nhp a ch Slave : 12. t thi gian ch ni tip :
P2011 index 0 = t 0 n 31 P2014 index 0 = t 0 n 65.535 ms
13. Truyn da liu t RAM n EEPROM. 14. P0971 = 1 (bt u truyn )Lu thay i tham s vo EEPROM.
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4.2.3. Cc lnh ca th vin USS library :

USS_protocol library l mt th vin lp trnh cho giao thc USS vi cc CPU m SIEMENS a ra v c tch hp trong Step7-MicroWIN (t version 3.2 tr ln). Th vin ny c tt c 8 lnh, ta ch vic ko cc hm t th vin ra s dng. Ta s i tm hiu lt cc lnh c bn ca th vin :
ln
Lnh USS_INIT :
Lnh c s dng nh ngha giao thc truyn thng gia PLC vi bin tn. EN (Enable) : l chn kch hot cho lnh lm vic. Thng thng trong chng trnh s dng, chn EN ch nn kch hot 1 ln cho 1 bin tn. Mode : chn chn ch cho giao thc : = 0 : giao thc PPI. = 1 : giao thc USS. Baud : chn chn tc truyn : 1200, 2400, 4800, 9600 Active : chn chn bin tn no ch kch hot. Mi bin tn khi ni trong mng c nhn 1 a ch t 0 n 31. Gi tr ny c lu trong 1 t nh :
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Khi lnh USS_INIT hon thnh, bit Done dng ln 1 v tnh trng thc hin lnh c lu tr trong byte Error. Gi tr byte Error c th c tra trong bng sau cho bit c tnh trng thc hin lnh :
Lnh USS_CTRL :
Lnh c s dng iu khin mt ng c c ghp ni vi bin tn ch kch hot.
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EN (Enable) : l chn kch hot cho lnh hot ng. Do chn En lun mc cao trong qu trnh bin tn hot ng. RUN : Khi RUN = 1, bin tn bt u chy ng c theo tc v chiu quay t trc. Khi RUN = 0, bin tn dng ng c. OFF2 & OFF3 : khi cc chn ny = 1, ng c s c dng nhanh hoc t t ty theo ch c chn. F_ACK : bit s dng bo cho bin tn bit cc li c xa. DIR : bit iu khin chiu quay ng c : = 0 : quay thun. = 1 : quay ngc. Drive : chn chn a ch ca bin tn c iu khin. Type : chn chn loi bin tn : = 0 : bin tn MM3. = 1 : bin tn MM4. Speed_SP : l tc t ca bin tn, c di t -200% n +200%. (v d : ta t tn s max = 50Hz. Nu ta t Speed_SP = 50.0 th bin tn s iu khin tc ng c t setpoint = 25Hz.) Status : l t trng thi lu gi cc thng tin v giao tip gia PLC v bin tn. Speed : hin th tc ca ng c (-200% n +200%) Run_EN : chn bo trng thi ca ng c : = 1 : ng c ang chy. = 0 : ng c ang dng. D_Dir : hin th chiu quay ca ng c. Inhibit : bit hin th trng thi cho php/khng cho php hm trn bin tn. Error & Fault : hin th trng thi li. Lnh USS_RPM_x : Lnh dng c gi tr mt tham s ca bin tn. Gm 3 lnh c : USS_RPM_W : Lnh c tham s l mt t n khng du.
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USS_RPM_D : Lnh c tham s l mt t kp khng du. USS_RPM_R : Lnh c tham s l mt s thc.
EN : (Enable) bit ny phi c bt trong sut qu trnh thc hin lnh. Ch rng trong mt thi im ta ch c th s dng lnh c hoc lnh ghi, khng th va c li va ghi ln bin tn c. XMT_REQ : Lnh yu cu c tham s mi khi c sn ln chn ny. Drive : l a ch ca bin tn. Param & Index : l gi tr index v tham s cn c. DB_Ptr : a ch b m 16 bytes lu tr gi tr trung gian trong qu trnh thc hin lnh. Done : khi lnh lthc hin xong, bit ny s c set ln 1. Error : byte cha tnh trng li khi thc hin lnh. Value : gi tr ca tham s cn c c tr v. Lnh USS_WPM_x : Lnh dng ghi gi tr cho mt tham s ca bin tn. Gm 3 lnh : USS_WPM_W : Lnh ghi tham s l mt t n khng du. USS_WPM_D : Lnh ghi tham s l mt t kp khng du. USS_WPM_R : Lnh ghi tham s l mt s thc.
EN : (Enable) bit ny phi c bt trong sut qu trnh thc hin lnh. Ch rng trong mt thi im ta ch c th s dng lnh c hoc lnh ghi, khng th va c li va ghi ln bin tn c. XMT_REQ : Lnh yu cu ghi tham s mi khi c sn ln chn ny. EEPROM : bit cho php hoc khng cho php lu gi tr va ghi vo EEPROM. Drive : l a ch ca bin tn. Param & Index : l gi tr index v tham s cn c.
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Ngnh iu Khin T ng
DB_Ptr : a ch b m 16 bytes lu tr gi tr trung gian trong qu trnh thc hin lnh. Done : khi lnh lthc hin xong, bit ny s c set ln 1. Error : byte cha tnh trng li khi thc hin lnh.
4.3. Ghp ni PC v PLC :

4.3.1. Kt ni ngun CPU S7-200 :
Cng vic u tin khi ghp ni PC v PLC l kt ni ngun ca CPU S7-200. Cn lu n in p ngun cung cp cho CPU v d nh trn CPU ghi DC/DC/DC th ch c cp ngun 24V cho n. Cn i vi loi AC/DC/RLY th chng ta c th cp ngun xoay chiu cho n. Phi tt CPU trong sut qu trnh u ni v l do an ton v trnh hng thit b.
Hnh 4.4: Kt ni ngun vi CPU S7-200
4.3.2. Kt ni cp RS-232 / PPI Multi Master :

Hnh 4.5 a ra cch ni cp RS-232/PPI Multi Master t S7-200 n thit b lp trnh. - Ni u RS-232 (nh du l PC) ca cp RS-232/PPI Multi Master n cng truyn thng ca thit b lp trnh. - Ni u RS-485 (nh du l PPI) ca cp RS-232/PPI Multi Master n cng 0 (port 0) hoc cng 1 (port 1) ca S7-200. - Ch kha DIP ca cp RS-232/PPI Multi Master c t nh hnh 3.5.
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Hnh 4.5 : Ghp ni cp RS-232/PPI Multi Master.
4.3.3. Thit lp cc thng s truyn thng :

Ta c th s dng STEP7-MicroWIN thit lp cc thng s cho truyn thng nh sau : - Khi ng STEP7- Micro/WIN m mt project mi. - Click vo biu tng Set PG/PC Interface => chn PC/PPI cable(PPI) => Properties... - Trong ca s Properties-PC/PPI cable(PPI), tab PPI cho php ta ci t cc thng s v a ch trm, tc truyn,... Cn tab Local Connection cho ta khai bo cng truyn thng ni trn my tnh.
Hnh 4.6. Thit lp cc thng s truyn thng.
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kim tra PLC c kt ni vi PC hay cha, ta Click vo biu tng Communications thanh Navigation hin th hp thoi Communications. Sau khi khai bo a ch v tc baud => Double-Click to Refresh ta s thu c kt qu cc CPU PLC c kt ni.
Hnh 4.7. Ca s Communications Nu STEP7 Micro/WIN khng tm thy PLC no, kim tra ci t cho tham s truyn thng v lm li nhng bc ny. Sau khi thit lp truyn thng vi S7-200, ta c th lp trnh, down load, up load chng trnh t PLC.
4.4. Kt ni WINCC v PLC S7-200 :

Khi xy dng mt mn hnh gim st vi PLC S7-200, ta cn phi kt ni WINCC v PLC c th a c cc tags ngoi t PLC vo WINCC theo di. Vic kt ni ny c tr gip nh s dng chng trnh S7-200 PC Access v thng qua giao thc OPC. Cc bc tin hnh nh sau : B1. Khi ng S7-200-PC Access => Click chut phi vo MicroWin => chn New PLC :
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t tn v a ch ca PLC. a ch PLC c th t t 1-126 phn bit cc trm PLC khc nhau.
B2. to Tag cho cc trm PLC ta Click chut phi vo PLC cn to Tag => chn Folder to nhm Tag / chn Item to Tag ring r.
t tn cho Tag (ch n ID ca Tag). Sau chn a ch ca Tag trn vng nh ca PLC. Cng c th la chn kiu Tag l ch c/ch vit/va c va vit.
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* CH : Ta c th Add nhanh mt nhm cc Tag t chng trnh PLC bng cch : Khi vit chng trnh trn STEP7-Micro/WIN ta s dng Symbol Table t tn cho cc a ch ( a ch ca Tag trn PLC ) di dng cc Symbol ( cng chnh l tn ca Tag trong PC ACCESS ):
T Menu ca PC Access vo File => chn Import Symbols ri chn ng dn n chng trnh iu khin.
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Nh vy cc Symbol s c add vo PC ACCESS di dng cc Tag trong 1 nhm :
B3. Khi ng WinCC => To mt project mi : Click chut phi vo TagManagement => chn Add New Driver. => Chn OPC.chn ca s xut hin.
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B4. Click chut phi vo OPC Groups => chn System Parameter => mn hnh OPC Item Manager xut hin => Click chut vo LOCAL. Nu h thng ci t PC ACCESS thnh cng th chng trnh s t ng tm ra OPC Server ( S7200.OPCServer ).
B5. To mt kt ni mi bng cch Click chut phi vo OPC Groups => chn New Driver Connection => t tn cho kt ni.(V d : S7200)
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B6. Click chut phi vo kt ni => Ca s Connection properties hin ra. Chn Properties
Trong ca s Properties xut hin nh tn OPC Server :
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Click chut tri vo Test Server=> Thnh cng
B7. a Tag trong PC ACCESS vo WinCC bng cch to 1 Tag kt ni vi Tag cn a : Click chut phi vo kt ni chn New Tag
t tn v chn kiu d liu cho Tag ( Ch kiu d liu phi ph hp vi kiu ca Tag s c lin kt ).
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Click chut vo nt Select chn a ch Tag s c lin kt. y chnh l ID ca Tag trong PC ACCESS.
Nh vy Tag Run trn WinCC c lin kt vi Tag run trn PC ACCESS. ** CH : Ta c th a cc Tag t PC ACCESS vo WinCC bng cch sau : Sau khi to cc Tag trn PC ACCESS v to OPC Server thnh cng ( bc 1-4 ). Trong ca s OPC Item Manager Click chut vo S7200.OPCServer => Click chut vo nt Browse Server
Chn Next ( C th chn Type chn Tag c kiu cn thit ).
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Ca s S7200.OPCServer xut hin => chn Tag cn a vo WinCC ri Click nt Add Items.
H thng yu cu to mt kt ni OPC => Chn Yes ri t tn cho kt ni => Finish.
Sau khi kt ni, ta c th s dng cc tag ngoi (c link trc tip n cc vng nh ca PLC) nh cc tag ni trong WinCC.
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Chng V : NG DNG VO IU KHIN NG C QUT LM MT CLINKER

5.1. Cu trc h thng v bi ton cng ngh :
5.1.1. Cu trc h thng :
Lm mt clinker l mt cng on trong dy chuyn sn xut xi mng, do h thng iu khin cc qut my lnh cng l mt phn ca h thng ca nh my. Cu trc ca h thng bao gm : H thng cc trm my tnh phng iu khin trung tm : OS (Operator Station), ES (Engineer Station), AS (Automation Station) c ni vi nhau v vi cp di nh mng Ethernet. Trm vn hnh v gim st cng on lm mt, gm PLC v mn hnh gim st. Cc thit b iu khin cp trng v thit b trng : Bin tn v qut lm mt.
Hnh 5.1 : Cu trc h thng iu khin.
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Nh vy, vai tr ca bin tn y chnh l mt thit b iu khin cp trng, m bo iu khin ng c cc qut mt cch chnh xc. Cn PLC v PC ng vai tr l mt b iu khin v gim st.
5.1.2. Bi ton cng ngh :

Nh phn tch chng trc, m bo cht lng ca clinker ra khi l, mt yu cu rt quan trng trong qu trnh lm mt clinker l phi m bo t l p sut cng nh lng gi so vi lng clinker t mt gi tr nht nh ty theo yu cu cng ngh ca tng dy chuyn sn xut. Do , bi ton t ra chnh l iu khin p sut ca cc qut gi theo gi tr t trc. Gi tr t y, c th do my tnh phng iu khin trung tm tnh ra ( ch Auto) hoc do ngi vn hnh n nh qua mn hnh iu khin gim st ( ch Manual). Ngoi ra, cn phi gim st c cc thng s qu trnh ca cng on lm mt.
5.2. Lp trnh h thng :

Thit k chng trnh PLC l mt phn rt quan trng trong vic thit k h thng iu khin, y chnh l phn m ngi lp trnh s tin hnh trin khai cc bi ton cng ngh bng chng trnh iu khin. H thng vn hnh c tha mn yu cu cng ngh ra hay khng ph thuc rt nhiu vo chng trnh iu khin. T yu cu ca bi ton t ra, ta xy dng s nguyn l ca h thng iu khin qut lm mt nh sau :
Hnh 5.2 : S nguyn l h thng iu khin. H thng s dng b iu khin PID mm tch hp sn trong PLC S7-200 : Gi tr t t my tnh trung tm hay t ngi vn hnh (ty ch vn hnh) v gi tr o thc t phn hi v sau khi chuyn i kiu s l tn hiu u vo (sp v pv) cho b PID. u ra sau khi tnh ton ca b PID chnh l gi tr t cho bin tn, v c a ti bin tn nh iu khin USS. Bin tn c kh nng iu khin ng c tng i chnh xc theo gi tr t. Nh vy h thng s t ng iu chnh p sut ca qut theo gi tr t trc.
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n Tt Nghip Cc thut ton iu khin v gim st : Thut ton iu khin cc qut :
Ngnh iu Khin T ng
Thut ton gim st cc thng s :
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Thut ton cnh bo nhit :
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Chng trnh lp trnh iu khin chi tit cho PLC c trnh by chi tit trong phn ph lc.
5.3. Thit k giao din vn hnh :

Giao din vn hnh c thit k trn phn mm WinCC-v6.0. Giao din HMI ca cng on lm mt clinker s m t v gim st ton b h thng c gn lin vi cc bin qu trnh (process tags) di dng cc tag name trao i d liu vi PLC. Sau khi h thng c lp trnh s c link vi WinCC di dng cc External tags iu khin cc i tng c thit k trn WinCC. Vic iu khin c thc hin qua vic lin kt gia cc i tng vi cc tag name. Yu cu ca mt mn hnh gim st phi m bo tnh thng tin, v thn thin vi ngi vn hnh. N phi phn nh c hnh nh ca qu trnh, v gip ngi vn hnh c th theo di cc thng tin cng nh c th s dng, iu khin mt cch d dng. Giao din vn hnh ca cng on lm mt clinker c thit k bao gm 1 mn hnh giao din qu trnh v 14 mn hnh trng thi cho 14 qut lm mt. C th :
5.3.1. Mn hnh giao din qu trnh :

- M t : Mn hnh giao din qu trnh m t ton b qu trnh cng on lm mt clinker, bao gm cc thit b ca h thng lm mt : bung l, cc qut lm mt (s lng, v tr tng i trong h thng), h thng bng ti clinker, my lc bi tnh in, h thng lm mt bng nc,v cc nt chc nng cho ngi vn hnh iu khin. - Chc nng : Mn hnh giao din qu trnh l ci nhn ton cnh ca qu trnh lm mt clinker. Gip cho ngi vn hnh c th nm c quy trnh hot ng ca cng on lm mt, gim st cc thng s ca qu trnh (cc gi tr p sut ca cc qut, p sut tng trong l, tc dch ghi, nhit u ng gi nng 3). Cc nt chc nng cho php ngi vn hnh chn ch hot ng, kim tra trng thi ca cc qut lm mt v c th dng khn cp h thng nu cn thit.
5.3.2. Mn hnh trng thi ca qut lm mt :

- M t : C tng cng 14 mn hnh hin th trng thi ca 14 qut lm mt tng ng. Mi mn hnh bao gm : cc nt chc nng la chn mn hnh ca qut lm mt cn theo di, cc thng s p sut qut (di lm vic, gi tr t, gi tr thc), v th qu trnh. - Chc nng : Mn hnh trng thi ca cc qut c th c truy nhp t mn hnh giao din qu trnh bng nt chc nng hay bng cch click p vo biu tng qut
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lm mt cn theo di, hoc cng c th chuyn i qua li gia cc mn hnh bng cc nt chc nng trn mn hnh trng thi bt k. Mn hnh trng thi cho php ngi vn hnh theo di gi tr p sut ca qut lm mt (di p sut ca qut, gi tr t, gi tr thc) v th hin th qu trnh p ng ca p sut thc theo gi tr t nh b iu chnh PID. ng thi, cho php ngi vn hnh c th t trc tip gi tr t p sut cho cc qut trong ch Manual. Cc hnh t 5.3 n 5.6 s m t chi tit cc mn hnh vn hnh gim st ca cng on lm mt clinker.
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Hnh 5.3 : Mn hnh giao din qu trnh lc khi ng v ch dng.
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Hnh 5.4 : Mn hnh giao din qu trnh khi hot ng.
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Hnh 5.5 : Cnh bo khi nhit u ng gi nng 3 qu cao.
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Hnh 5.6 : Mn hnh trng thi ca qut lm mt (Fan 01).
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KT LUN
Sau thi gian nghin cu v lm n vi ti: ng dng bin tn tit kim nng lng cho h thng qut my lnh lm mt Cliker trong nh my xi mng. Chng em t c mt s kt qu sau:
- Nm c dy chuyn cng ngh sn xut ca nh my xi mng v nguyn tc

hot ng ca cng on lm mt Clinker.
- Nghin cu 2 phn mm ca SIEMENS: WinCC v6.0 v STEP7-MICROWIN

v4.0, v s dng thnh tho 2 phn mm ny xy dng giao din vn hnh cho cng on lm mt clinker.
- Thit k thnh cng h thng iu khin cc qut lm mt cho cng on lm

mt Clinker ca nh my xi mng.
- Dng h thng gm PC v PLC S7-200 CPU 226 v02.01 kt ni vi bin tn

MM440 m phng thnh cng bi ton vi i tng thc. Hng pht trin ca n:
- Thit k giao din vn hnh cho cc cng on cn li ca nh my.

- Tin ti hon thin v a h thng ra thc t.
- M rng v pht trin ti theo hng nghin cu thit k h thng ghp ni

PLC Bin tn iu khin ng, trong : iu khin trc tip ng c nh b PID tch hp sn trong bin tn, v cc tham s ca b PID ny s c t ng chnh nh nh PLC (s dng FUZZY ca PLC chnh nh thch nghi cc tham s PID ca bin tn).
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PH LC : Chng trnh iu khin gim st cng on lm ngui clinker

* T chc b nh : Address 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 M0.0 M0.1 M0.2 M0.5 M1.0 VD352 VW200 VD202 VW206 VD336 VD340 VD348 VD224 VD220 VD228 VD232 VD236 VD240 VD244 VD248 Symbol Auto_select Manu_select Stop_select Alarm_Tem RUN Comment La chn ch Auto La chn ch Manu La chn ch Stop Bit cnh bo nhit qu cao Bit iu khin Fan1
Auto_F1_setpoint Gi tr t cho Fan 1 ch Auto PID_pv PID_sp PID_out PRESS_TOTAL SPEED Gi tr phn hi t bin tn v cho b PID Gi tr t cho b PID u ra ca b PID Tng p sut ca cc qut Tc ghi l
TEMPERATURE Nhit gn ng gi nng 3 USS_SP SP_F1 RS_F1 SP_F2 RS_F2 SP_F3 RS_F3 SP_F4 Gi tr t USS ca bin tn 1 Gi tr t cho Fan 1 Gi tr thc ca Fan 1 Gi tr t cho Fan 2 Gi tr thc ca Fan 2 Gi tr t cho Fan 3 Gi tr thc ca Fan 3 Gi tr t cho Fan 4
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n Tt Nghip 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 VD252 VD256 VD260 VD264 VD268 VD272 VD276 VD280 VD284 VD288 VD292 VD296 VD300 VD304 VD308 VD312 VD316 VD320 VD324 VD328 VD332 RS_F4 SP_F5 RS_F5 SP_F6 RS_F6 SP_F7 RS_F7 SP_F8 RS_F8 SP_F9 RS_F9 SP_F10 RS_F10 SP_F11 RS_F11 SP_F12 RS_F12 SP_F13 RS_F13 SP_F14 RS_F14
Ngnh iu Khin T ng Gi tr thc ca Fan 4 Gi tr t cho Fan 5 Gi tr thc ca Fan 5 Gi tr t cho Fan 6 Gi tr thc ca Fan 6 Gi tr t cho Fan 7 Gi tr thc ca Fan 7 Gi tr t cho Fan 8 Gi tr thc ca Fan 8 Gi tr t cho Fan 9 Gi tr thc ca Fan 9 Gi tr t cho Fan 10 Gi tr thc ca Fan 10 Gi tr t cho Fan 11 Gi tr thc ca Fan 11 Gi tr t cho Fan 12 Gi tr thc ca Fan 12 Gi tr t cho Fan 13 Gi tr thc ca Fan 13 Gi tr t cho Fan 14 Gi tr thc ca Fan 14
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* T chc chng trnh chnh v cc khi chng trnh con : Program Block OB1 SBR0 SBR2 SBR3 -> SBR16 SBR17 -> SBR30 SBR31 SBR37 Symbol MAIN Auto_mode Manu_mode Auto_F1 -> Auto_F14 Manu_F1 -> Manu_F14 Total Temp Comment Chng trnh chnh Chng trnh cho ch Auto Chng trnh cho ch Manu Chng trnh con iu khin cc qut Fan 1 -> Fan 14 ch Auto Chng trnh con iu khin cc qut Fan 1 -> Fan 14 ch Manu Chng trnh con tnh tng p sut cc qut Chng trnh con cnh bo khi nhit u ng gi 3 cao qu mc cho php
* Ci t tham s cho b iu khin PID : Trong PLC S7-200 c tch hp sn b iu khin PID mm, ta c th to v s dng cng c ny bng cch tin hnh nh sau : - Click vo Wizards => Click p vo PID => Ca s Instruction Wizard PID xut hin => Chn b PID cn to ri Next.
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- Nhp gi tr cc tham s P, Ti, Td, thi gian trch mu cu hnh cho b PID : ( y gi tr : P = 3.0; Ti = 0.01 min; Td = 0; thi gian trch mu 0.1s) => Next
- Gii hn gi tr PV (process variable) v u ra ca b PID => Next
- Suggest Address to ra 1 vng a ch trn PLC cho vic lu tr, tnh ton ca b PID => Next => ... => Finish
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n Tt Nghip * Chng trnh iu khin :
Ngnh iu Khin T ng
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DANH MC TI LIU THAM KHO

[1] [2] [3] [4] [5] [6] [7] [8] Siemens WinCC v6.0 SP4 software. Siemens STEP 7 MICROWIN32 V4.0.0.18 software. www.siemens.com Ti liu ca cng ty xi mng Bm Sn. Hong Minh Sn : Mng truyn thng cng nghip- NXB KHKT. Hong Minh Sn : Bi ging - H thng iu khin phn tn 2006. Hong Minh Sn : iu khin qu trnh NXB KHKT. Nguyn Don Phc- Phan Xun Minh :T ng ha vi SIMATIC S7-200 NXB KHKT. [9] Nguyn Don Phc : L thuyt iu khin tuyn tnh NXB KHKT. [10] OPC Foundation: OPC Data Access Custom Interfaces Specification 2.0. [11] SIEMENS Universal Serial Interface Protocol : USS Protocol. [12] Hng dn s dng bin tn MM440 SIEMENS Vit Nam.
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Lam Mat Clinker

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n Tt Nghip

- Tm hiu cu trc nguyn l cng on lm mt clinker.

Chng I : CNG NGH SN XUT XI MNG PORTLAND

1.2. Nguyn liu, nhin liu sn xut clinker xi mng :

Ph gia thy : lm tng tnh cht bn nc ca xi mng.

Ph gia in y : nhm tng nng sut, h gi thnh sn phm.

1.2.2. Nhin liu s dng trong nh my xi mng :

1.3. Cng ngh sn xut xi mng :

Hnh 1.1 : S tng quan dy chuyn cng ngh sn xut xi mng.

Tn nguyn liu vi t st X l cao Than

m vo my (%) <2% <2% <2% <2 3%

Ch thch : 1. 2. 3. 4. Lc bi ti. ng cp liu. Bung trn. Phn t sc kh.

1.3.2.Giai on 2: Nung hn hp phi liu thnh clinker v lm mt clinker:

Bng 1.2 : Thnh phn khong clinker theo tc lm mt.

1.3.3. Giai on 3 : Gia cng, v nghin clinker vi cc ph gia khc.

Tip tc lm ngui clinker n nhit thng.

Hnh 1.6 : S cng ngh cng on nghin xi mng.

Hnh 1.8 : S cng ngh cng on ng bao xi mng.

1.4. c im c bn ca dy chuyn cng ngh sn xut xi mng:

1.5. Cc ch tiu cn t c trong qu trnh sn xut xi mng :

1.5.1. Ch tiu v sut tiu hao nng lng :

Kcal/ Kg 700 850 KWh/ T KWh/ T 37 45 30 38

Bng1.3 : Ch tiu v sut tiu hao nng lng.

1.5.2. Ch tiu pht thi ra mi trng :

Bng 1.4 : Ch tiu pht thi ra mi trng.

1.5.3. Ch tiu v n nh cht lng sn phm : 21

3200 3600 2.0 4.0 1.5 0.5 45 55

Bng 1.5 : Ch tiu v n nh cht lng sn phm..

Chng II : CNG ON LM MT CLINKER

Hnh 2.1 : H thng lm lnh kiu ghi.

Hnh 2.2 : H thng lm lnh kiu hnh tinh.

Hnh 2.3 : H thng lm lnh l quay h t.

2.2. Cng ngh lm mt clinker kiu ghi :

2.2.2. Nguyn l lm vic ca my lm mt kiu ghi :

1. Nhit ca clinker ra khi my lm mt : Hin nay t c trn 65oC

2. Hiu sut thu hi nhit ca my lm mt. 27

3. Lu lng khng kh lnh cp cho my lm mt clinker bng cc qut

2.3. xut gii php tit kim nng lng :

Chng III : GII THIU V MT S THIT B V PHN MM NG DNG

3.1.2. Cc u dy iu khin v s nguyn l :

n Tt Nghip 20 21 22 23 24 25 26 27 28 29 30 DOUT1/COM DOUT2/NO DOUT2/COM DOUT3/NC DOUT3/NO DOUT3/COM DAC2+ DAC2P+ N-

Bng 3.1 : Cc u dy iu khin ca MM 440.

Hnh 3.2 : S nguyn l MM 440.

3.1.3. Cch ci t tham s ca bin tn :

Cc ngun lnh P0700 = 2 (u vo s) Ngun im t P1000 = 2 (u vo tng t) Ch lm mt ng c P0335 = 0.

Cc u ni 5 6 7 8 16 17 Qua u tng t s 1 Qua u tng t s 2

Thng s P0701 = 1 P0702 = 12 P0703 = 9 P0704 = 15 P0705 = 15 P0706 = 15 P0707 = 0 P0708 = 0

Chc nng ON/OFF1 - (I/O) o chiu Xa li im t c nh im t c nh im t c nh Khng s dng Khng s dng

Bng 3.2 : Cc u vo s ca MM 440.

Truy nhp thng s Tng gi tr

n nt ny cho php ngi s dng c th truy nhp n cc thng s n nt ny lm tng gi tr c hin th

Gim gi tr n nt ny lm gim gi tr c hin th

Dng in nh mc ca ng c Di dng in t 0.12 A n 10000A

Cng sut nh mc ca ng c Di cng sut t 0.01 n 2000 [KW/Hp]

n Tt Nghip 15 Chn tn s c nh 4(xem P1001)

3. Chn m nh phn + Lnh ON (P0701 P0703 = 17)

Tn s c nh 2 Xem chi tit P1001

Tn s c nh 3 Xem chi tit P1001

Tn s c nh 4 Xem chi tit P1001

Tn s c nh 5 Xem chi tit P1001

Tn s c nh 6 Xem chi tit P1001

Tn s c nh 7 Xem chi tit P1001

P1080 P1082 P1120

Tn s t nh nht Tn s t ln nht Thi gian tng tc