PLC For Batch Control Process

Introduction:

PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial computer control system that constantly monitors the input of device inputs and makes decisions based on a custom output control system for output devices. Almost any production line, machine function, or process can be greatly improved using this type of control system. However, the main advantage of using PLC is the ability to change and replicate the operation or process while collecting and transmitting important information. Another advantage of the PLC system is that it is modular. That is, you can mix and match types of input and output devices to better fit your app.

 

How does the PLC work?

PLC detects information on connected sensors or input devices, processes data, and triggers output based on predefined parameters. Depending on the input and output, PLC can monitor and record operating time data such as machine production or operating temperature, automatically start and stop processes, generate alarms if the machine is not working properly, and much more. Programmable Logic Controllers are a flexible and robust, flexible control solution for almost any application.

 

Four Steps to Performing PLC

1.) Input Scan

Detects the status of all input devices connected to PLC

2.) System Scan

Uses the concept of a user-created program

3.) Output Scan

Enables or disables all output devices connected to PLC.

4.) Maintenance of housing

This step includes links to editing terminals,

internal inspection.

Why is batching important?

Integration helps with quality control. As the collection is completed, QC processes are applied and the bulk is thoroughly tested. Any deviation from the specification sheet allows the plant to discard the pile, remove the problems that caused the deviation and proceed to the new pile. This reduces the amount of waste that can be created.

Integration allows the factory to control production performance based on demand. In other words, customers will usually request a limited amount of a particular product. When the run is complete, the production team will clean up the equipment, install new collection parameters and start a new run.

Introduction to Batch Processing

In general, there are two types of processes in production: discrete and analog. A different process is a production process that will produce different widgets. In other words, the production line may produce one item, two items, three items, etc. An analog production process is when a plant will create a product that can be measured by weight. Examples include the production of beverages, sauces, uncooked ingredients, etc. While it is possible to design a flow that will produce a continuous product, such production is often managed in batches. It is important to note that although collections are considered analog or continuous flow, most of them end up packaged for use which transforms them into a varied production process.

A collection is a specific volume of product that must be produced simultaneously. Let's look at a very simple example of a collection: A mixing tank consists of two feed pipes from a water source and a delicious syrup respectively. The user is able to turn on the flow of water or sweet syrup in the mixing tank. In this case, the batch would be an act of creating a certain mixture of two substances placed in a mixing tank. For example, a collection can be defined as 5000 pounds of water and 200 pounds of sweet syrup. A separate collection may contain 4500 pounds of water and 700 pounds of syrup. Note that although the total weight is the same in both cases, it may differ between groups.

PLC example of group control -

To better understand the process of mass production, let's look at a simple system. a mixing tank that receives a set of ingredients is that basic example of a collection process. In this section, we will look at a PLC planning model that controls a tank full of three ingredients.

Step 1 - Input, Output and PLC System Structure

Let's start by understanding the system. Our PLC unit controls the set of input valves, the discharge valve, receives information about the amount of fluid we send to the tank (via a simulated flowmeter), displays basic information about the system and allows operators to send the components to the tank. tank. Here are the basic divisions for this program

Step 2 - HMI Controlled Batching

In a system without batch control, the operator needs to open one valve and monitor the flow until it reaches a certain point of storage. At that point, he closed the valve and proceeded to the next ingredient. In a control system with a blending feature, the operator will set the quantity for each ingredient or select a batch recipe. The system would take care of something else.

The HMI control screen shown below is used for startup, stop, release and targeted mass setup. Note that although the operator can adjust the target at any time, the appropriate buttons are disabled in some cases. The user can only start the batch if the tank is empty.

 

Step 3 - Integrating PLC Programming

Once the accumulation has started, we need to track our ingredients against the goals set by the operator on HMI. Logic is simple in this; we open the valves while the value we received is below the target and close the valves when we reach the title. The rung below shows how we achieve this with ladder logic. Additionally, the rung will set the "Batch Complete" bit when all the ingredients have reached their place.

Benefits of Using PLC in Collection Management Procedure: -

1. reduction in production time.

2. Decreased fertility соst.

3. Increased quality and volume of рrоduс.

4. Energy efficiency соnsumрtiоn.

Restrictions on Using PLC in Collection Management Procedure: -

1. Evil includes:

2. Each cluster may be subject to careful quality control and guarantees, which may result in increased staff downtime.

3. Increased maintenance costs for a large number of manufactured products.

4. Errors with the product produced will create wasted time and cost

                              

Conclusion

Blending plays an important role in chemicals, food, beverage and other forms of production processes. Creating a simple integration plan is the best PLC Planning Project for everyone reading PLC and HMI program. Not only are these apps used in real applications, they offer the editor many challenges that can be applied to many other applications and help the editor learn new skills.