Reynosa Operations perations

PROJECT DESCRIPTION

SCADA SYSTEM MONITORING AND CONTROL OF JING DAY PRESS PRESS

Engineer: David Aldana Tolentino Maintenance Supervisor Phone: 9 29 36 00 Ext.: 352 Email: daldana@mnrubber.com

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TABLE OF CONTENTS
1. 2. 3. GENERAL ........................................................................................................................................................................................ 2 INTRODUCTION............................................................................................................................................................................ 2 GENERAL DEFINITIONS ............................................................................................................................................................ 3 3.1. 4. 5. TERMINOLOGY USED................................................................................................................................................................... 3

PROCESS ENVIRONMENT ......................................................................................................................................................... 5 SYSTEM REQUIREMENTS INSTALLATION .......................................................................................................................... 5 5.1. 5.2. GENERAL REQUIREMENTS ................................................................................................................................................. 5 HARDWARE: ........................................................................................................................................................................... 5

6. 7. 8. 9.

SOFTWARE..................................................................................................................................................................................... 8 INSTALLATION ........................................................................................................................................................................... 10 SUPPORTING DOCUMENTATION .......................................................................................................................................... 12 METHOD OF USE ........................................................................................................................................................................ 12 9.1. CONNECTION TO SCREEN ................................................................................................................................................. 12 TRAINING ................................................................................................................................................................................. 12

10.

10.1. WORK INSTRUCTION ...................................................................................................................................................... 12 10.1.1. Operator ........................................................................................................................................................................... 12 11. MONITORING .......................................................................................................................................................................... 13 CHANGING PARAMETERS: ............................................................................................................................................ 13 DATABASE: ....................................................................................................................................................................... 17

11.1. 11.2. 12.

ADVANTAGES: ........................................................................................................................................................................ 19 MODIFICATION OF SCREENS, DEPENDING ON THE NEEDS: ............................................................................................ 19 TIME DECREASE IN PROCESS TROUBLESHOOTING ................................................................................................ 19 VERIFICATION COMPLETE CYCLES: .................................................................................................................................. 19

12.1. 12.2. 12.3. 13.

POSSIBLE FAILURES / DISADVANTAGES ....................................................................................................................... 19 BUMPS PROGRAMMING ................................................................................................................................................. 19 NETWORK DISCONNECTION .................................................................................................................................................. 19

13.1. 13.2. 14.

REVIEWS................................................................................................................................................................................... 19

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1.

GENERAL

1.1.1.1. PURPOSE: To facilitate the diagnosis and monitoring of failures (for temperature or mechanical) in the presses Jing Day, through an interface accessible from any standard PC, being possible to manage remotely using the private network of the plant. 1.1.1.2. They involved the areas of Engineering, Production, Maintenance and Management, as they are directed to the project and will be performing and managing the information provided by this system. . 1.1.1.3. APPROVAL: The system will be evaluated by the above areas and hence will be generated depending on revisions and improvements that will give the final authorization management, depending on your own judgment in terms of cost / efficiency. .

2.

INTRODUCTION
2.1.1.1. Due to problems of power machinery and uncertainty of not knowing what causes the failure to overhaul the required hours, it was decided to develop a system that could automatically monitor key events of the press, and to see them the most "friendly" as possible. Specifically, we look for a way to record real-time efficiency of each bench press resistances, and to know on one screen all parameters handled, and they can be changed as indicated by the sheet process, without requiring further additional knowledge, (not knowing the meaning of the values N: 7 and the process to enter them on the screen of the press), only to have the process sheet should suffice. SCADA software was used from Allen Bradley (RS VIEW) for testing in one of the presses and found support for all PLCs Jing Day Machinery is fully compatible and functional. It tested its distribution on the local network via VNC (remote desktop) being remote data control of the press, using the laptop as a main computer maintenance, and client / user's computer production. Also use the software on a smartphone with Android operating system, and can be controlled using the mobile version of VNC software..

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3.

GENERAL DEFINITIONS
3.1. Terminology used 3.1.1.1. SCADA is a computer software that allows you to control and monitor industrial processes remotely. Provides real-time feedback to the field devices (sensors and actuators) and controlling the process automatically. Provides all the information generated in the production process (monitoring, quality control, production control, data storage, etc..) And allows management and intervention. 3.1.1.2. VNC: is a free software program based on a client-server which allows you to take control of the computer server remotely through a client computer. Also called remote desktop software. VNC does not impose restrictions on the server computer operating system with respect to the customer: it is possible to share the screen of a machine with any operating system that supports VNC connecting from another computer or device with a VNC client so wide management to with mobile phones (Smartphone) or between completely different systems, Windows, Linux, or Mac-Os. 3.1.1.3. PLC: An electronic device designed to program and control real-time sequential processes. Usually, you can find this type of equipment in industrial environments. 3.1.1.4. DH485: Communication protocol used by Allen Bradley PLC in its line of industrial control. It uses a number of devices or adapters to make the connection between PLC's and or computers that monitor and control the process. DH485 is a local area network (LAN) designed for applications in the manufacturing area. DH 485 can connect up to 32 devices, including SLC controllers, HMI devices and personal computers. 3.1.1.5. Link couplers: Device manager to connect the PLC to the DH485 network and controls the simultaneous interaction with PLCs and other computers on the network 3.1.1.6. RS VIEW: Scada software owned by Allen Bradley used on their devices natively. 3.1.1.7. LAN: is a computer network that interconnects computers in a limited area such as a home, school, computer laboratory or office building network media using either wireless or wired..

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Page 4of 19 3.1.1.8. PLUG IN (in the browser) is an application that relates to another to bring you a new function and usually very specific. This additional application is executed by the main application and interact through the API. Also referred to as plug-in (the English "[a] plug or insertion ') add-on (' added'), complement, or extension connector. 3.1.1.9. JAVA: Java is a programming language for general purpose concurrent, class-based, object-oriented, which was specifically designed to have as few implementation dependencies as possible. His intention is to allow application developers write the program once and run on any device (known in English as WORA, or "write once, run anywhere"), which means that the code is executed on a platform need not be recompiled to run on another. In this case it is essential to work with the remote desktop. 3.1.1.10.KIOSK (interactive): An interactive kiosk (or interactive kiosk) is a computer in a public place that allows users to perform multiple actions. Also used as an information tool for business and marketing. At present, interactive kiosks often have touch screens. 3.1.1.11.IP Address: An IP address is a numerical label that identifies, in a logical and hierarchical to an interface (communication element / connection) of a device (usually a computer) within a network using IP (Internet Protocol) , which corresponds to the network layer of the OSI model. Example representation or address 192.168.21.96 10,128,001,255

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4.

PROCESS ENVIRONMENT
The system will work with a computer in the workplace as a kiosk connected to an interface that will connect to the backbone network to DH485 which presses Jing were connected through another day each interface independently. Placement will be given after If approved the project

5.

SYSTEM REQUIREMENTS INSTALLATION

5.1. GENERAL REQUIREMENTS

5.2.

HARDWARE:

5.2.1.1. CORE CABLE: cable type for cable installation must be Belden9842. This cable sheath and shielding and consists of two pairs of twisted wires and a ground wire. Nodes on the trunk cable are interconnected in a chain. The length of the trunk cable depends on the location of the nodes in your network, however, the maximum length is 4,000 feet (1220 meters). Your cable system is capable of connecting up to 32 devices

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5.2.1.2. Link couplers couplers connecting link devices (PLC) in the DH-485. You
must install a link coupler isolated for each node in the network (PLC's). The coupling depends on the type of device you are connecting to the DH485. In this case the coupler used is the 1747-AIC. In normal operation with the programmable controller connected to the coupler link, the processor provides power to both the coupler link as the peripheral device (DTAM, PIC, HHT), If you do not connect the processor to the link coupler, use a power 24 VDC power for class 2 power coupler and device link.

5.2.1.3.POWER SOURCES: We will use a power supply of 24 V to avoid

saturating the PLC. Can any of the two models shown below.

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Page 7of 19 5.2.1.4. Conventional computer: You must be as common as possible (no laptop for heating issues) but should also have wireless connection to avoid cuts by wiring fault and the area was found, possibly coupled with this most ideal as to avoid the cable network that would be required to connect directly to the network. And avoid damage incidents maneuvers or machinery. .

5.2.1.5. DH485 USB Adapter: Used to connect the PC to the network backbone, giving the possibility to connect to any standard pc backup in case of failure of the primary PC. In this case the UIC model Allen Bradley 1747

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Page 8of 19 6.1.1.1. VNC: use free software VNC (Ultra VNC) for connection between the host computer and the computer user / client (remote) or other device, which can be anyone operating within the plant and which is connected to the wired or wireless network. 6.1.1.1.1.Each computer is configured with an access code to the host PC and read or write properties depending on the limits that require administrators. 6.1.1.1.2.Optionally, you can configure remote access native Windows if desired to not use older software even with their limited device support different system.

6.

SOFTWARE

6.1.1.2. RS View32: SCADA Software brand ownership Allen Bradley is required to design all display functions and store the data. (License pending, we have the test only)

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Page 9of 19 6.1.1.3. RS Linx: Software that enables the connection between different types of devices from Allen Bradley and SCADA database on the host PC (full license)

6.1.1.4. WEB BROWSER: May be Internet Explorer or Firefox. Both must be installed and enabled to run Java Plugins remote access.

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7.

INSTALLATION
7.1.1.1. The system may accommodate a number of other devices of the same brand Allen Bradley through the network, This is an example of how couplers would therefore installed (Figure 1) as the whole network (Fig. 2).

FIG. 1 Couplers connection between each of the presses

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FIG. 2 Example of a network with different models DH485 PLC and PCs at once

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8.

SUPPORTING DOCUMENTATION
8.1.1.1. The setting and complete reproduction of this system to all the presses must be made with existing equipment because each dam requires personalization data to distinguish from each other. It will create more screens in the SCADA software for each press and configure their communications to the main computer. 8.1.1.2. Any doubt about the computer has enough support information page of the manufacturer which made the first connection to the presses today. http://literature.rockwellautomation.com/idc/groups/literature/documents/um/vw32-um001_-en-e.pdf http://www.rockwellautomation.com/resources/downloads/rockwellautomation/zip/support/pc-cards/1747-UIC.zip

9.

METHOD OF USE
9.1. CONNECTION TO SCREEN 9.1.1.1. Authentication: The connection is done through the commonly used browser (IE Explorer or Firefox), by IP and then the number of the access port. The way of writing is as follows 192.168.21.96:5800, which will be confirmed by the main computer and then ask for a password if required and also the user name (optional) depending on the level of security you require. This will only give access to the PC but the program must have started to manipulate the press, but is well just have a connection to the PC without any useful function. 9.1.1.2. Configuring clients / users: some computers may have production flaws in the browser and these are manifested when connecting to the host PC. Will be updated and enabled both the browser and the plug-ins of the same. (Java) and enlist each to the main computer. 9.1.1.3. ACCESS CONTROL SCREEN: This should start at the beginning of the operating system, and must be configured before any user connects production, At the moment there has enabled self starter and be done by the administrator of the main pc since is on probation, and will only be enabled when implemented the entire system.

10.

TRAINING
10.1.

WORK INSTRUCTION
10.1.1. Operator

A person must be assigned either the leader or manager to modify the parameters, in accordance with their superiors and model changes or development of each machine, as this is what will be in the physical presence to the press, trying be in sync with his superior, but also will be changed with conventional HMI screens with which the press has (DTAM model with lines of text).It is also recommended that the opening of the bumps that are needed to calibrate. And therefore the SCADA system is mostly supervisory set-up and made..

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11.

MONITORING
11.1. CHANGING PARAMETERS: The parameters for the set-up should be changed preferably from the host computer, remotely will only by engineering or production supervisors and mainly to review the state it is the press and previously communicated before any changes to production manager on duty, to avoid confusion. Below are the screens to be used by the system.

Fig.3 CHANGE AND MONITORING PARAMETERS Change Settings screen presses Jing day, from there you can access to view and change the mechanical movements of the press (bench piston vacuum chamber), auto mode, The parameters are as described in the instruction of this work to avoid further confusion with the PLC memory address as extra reference (N: 7) Temperature monitor has the right and switchable from the bottom buttons next to the texts SP (nominal temperature) and PV (actual temperature). The amount of cured and cured count can also be modified and reset from there.

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FIG.4 MONITOR INPUT AND SEQUENCE CURRENT Screen monitoring movements of the press and media status (faults and current sequence). Displays in the press that this mode (manual / automatic) and the action you are doing (healing, climbing etc ...), the progress of curing time now, and sensors that determine career movements of the press in circles small yellow (deactivated) and green (on). Accessories like the ejector and the bell will move graphically depending on your monitor and sensors that can be seen more easily if one of them is failing. By design not insert the remote control of the press for actions like pistons up and down as it is extremely hazardous to personnel in place. Only the person may do to the press with manual control. This screen will serve only as a monitor, not control.

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FIG.5 ENGINEERING PARAMETERS Display for advanced settings in the press, usually tolerances and times must unlock the parameters, this is done with a button.

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FIG.5 STATUS PRESSES

Screen to review who presses are active (on) and to access the menu via the button shown.

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11.2.

DATABASE: 11.2.1.1.HISTORY OF TEMPERATURES

Data recording what will the main computer and should only be deleted at the request of administrators assigned to the system, so far only the temperatures recorded in real time to a minute (volatile) and hour by hour, accumulating indefinitely latter in the historical database (Fig. 5). Any other extra record must be ordered in advance to see if it can be applied to SCADA

Fig.6 HISTORY OF TEMPERATURES Show all temperature changes per minute (real time) and hourly (stored in historical database), being able to view data from a week ago one month to one year depending on production needs. Shown in the graph of hour by hour

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11.2.1.2.CURE TIMES

There is a record of the duration of the cured and lost time between each pulse is symbolized as on and off, being able to see if there was too much delay between each other, or if the operator falls before press time.
.

Fig.7 CURE TIMES Display activations curing time and duration, represented as a linear pulse square wave, each wave length determines the time that remains on. .

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12.

ADVANTAGES:
12.1. MODIFICATION OF SCREENS, depending on the needs: 12.1.1.1.Can remove unwanted elements and add other user depending on their needs. It can modify the access security monitor if desired. It may increase the number of machines to the maximum specified (32 PLC's). 12.2. TIME DECREASE IN PROCESS TROUBLESHOOTING 12.2.1.1.It will decrease the time of diagnosis, and you can actually see which resistors banks are more efficient than others in relation to time / temperature even if you can see this in terminal stage each bank depending on your recovery time. They will if really its sensors are activated as they should and diagnose if you have a mechanical failure. 12.3. VERIFICATION complete cycles: 12.3.1.1.Operators may be down the presses before completing curing and curing time lost between each, eventually monitoring them during the shift and whether it causes faults in the material. .

13.

POSSIBLE FAILURES / DISADVANTAGES

13.1. BUMPS PROGRAMMING 13.1.1.1.Adjustment should be made to the press as it is necessary to see the opening, therefore depend on any console DTAM (screen used to date) installed at that time. 13.2. Network disconnection 13.2.1.1.The connection is made from a single computer so if it fails for any reason, causing users can not see any online media will only be modifiable to be present in the area. At the moment it is not recommended to transmit remotely outside the local network for security, and the VNC is only for local networks. In this case only within the plant can be used

14.

REVIEWS
Rev 1.1. It adds cured monitoring screen Is added active screen presses It modifies data entry mode

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