SCADA System for Assembly Unit Control System

ABSTRACTS Assembly unit function is complete the silos small cylindrical work piece placed in the assembly embedded into the hopper of the part to be assembled in the assembly process. In our PLC programming consists of 1 main network and 2 sub-routines network where the main network is used to simplify the connection between the 2 sub-routines network for supply process and assembly process. In SCADA application, assembly unit is control by HMI where its connected between MCGS software with PLC system.

1.0

INTRODUCTION

Assembly unit function is complete the black or white silos small cylindrical work piece placed in the assembly embedded into the hopper of the part to be assembled in the assembly process. The objective of this project is to demonstrate the process of assembly unit PLC control system and to expose student with basic pneumatic system and PLC programming. The composition assembly unit include tube-shape hopper, feeding agencies, transfer material sets, mechanical hand, to be assembled work piece positioning mechanisms, pneumatic system and valve, signal acquisition and automatic control system, as well as for electric connections the terminal row components, the entire production line status indicator lights and installation for the other institution of the aluminum bracket and the floor, the sensor mounting brackets and other accessories. 2.0 OBJECTIVE

Objective of this project are: a) To develop SCADA system for assembly unit by using MCGS software b) To monitor and control material feed, arm movement and process status of assembly unit c) To install alarm event for indicator status of material supply in assembly unit.

3.0

PROJECT DISCRIPTION

This project has been developing base on three main objectives. In order to achieve objective number one, the movement of tube silo and rotating platform is 3.1 ALARM EVENT

3.1.1 ALARM Alarm is one of critical part need to be considered in this assembly unit. The main parts of alarm events for assembly unit are for material supply condition during the process running. We created three conditions for alarm system. There are:

1) If material is sufficient Green light will ON 2) If material is insufficient Yellow light will ON 3) If no material Red light will ON 3.1.2 EVENT Event is normal operating mode. In automatic mode, machine running, green light is ON and if machine stop, red light is ON. In manual mode, machine running show by green light (tower) blinking and it machine stop, red light (tower) is ON. In addition, if machine in condition standby, the indicator light will ON and if any problem on machine occurs during the process running, red light will ON. This event is important to operator for them to know the condition of assembly machine unit. Auto mode 1) Run (Green Light 2) Stop Manual mode 1) Run 2) Stop 3.2 Configure and develop Human Machine Interface (HMI) of Assembly Unit System

3.2.1 Objectives of Assembly Unit HMI:I. II. III. Create and design HMI using MCGS Embedded Configuration Environment software for Assembly Unit system. Develop the configuration between the HMI and PLC unit S7-226 Siemens using PLC programming (STEP7-MicrowinV4.0) Test the HMI and PLC programming functionality according to the objective of assembly unit system.

3.2.2 Overview:The HMI of assembly unit has been developed using MCGS Embedded version environment software.

The screen contains the following aspect of monitor and control: Machine Status-RUN (Green Button) & STOP (Red Button) Process Indicator-Feed, Rotary platform and Pick & Place Alarm Indicator for supply-No material, Insufficient and Sufficient Digital clock

Results The first objective of HMI assembly unit process has been achieved, however the other two objectives does not meet the requirement of this learning module. Several problems that occurred during the project development are such as:1. Trainees cannot create the communication of HMI between the system units of Assembly Unit with Display Unit (Master).

2. Trainees do not fully understand on how to use the MCGS software to design the HMI system because the information and reference given are limited. 3. Because of the lack information and references, the configuration to perform the communication between HMI and PLC also cannot be done. 4. Some equipment and software used for this module are malfunction. Recommendations Some of prevention method needs to be considered for this HMI projects are:1. Provide a complete references or manual which easy to understand by trainees for this module. 2. Ensure the equipment and the systems are functioning before trainees can handle the material and equipment. 3. Use another of HMI software which is more friendly user. 4.0 4.1 PROCEDURE MCGS SOFTWARE

4.1.1 Steps to create and design new HMI layout using MCGSE software Several steps of procedure for creating the HMI design using MCGSE Embedded Configuration Environment software for Assembly Unit system are shown as below:-

1)Open MCGSE configuration icon

2) Click new icon>click ok

3) Click User Wind icon>Create

4) Click property box

5) Click name box>change window0 to Assembly_unit

6) Click Real Time DB box

7) Click new obj box

8) Click Device box

9) Right click at device configuration Box>click Device Toolbox

10) Double click serial_port and Siemens_S7200PPI

kn 11) Click User Wind box>open assembly_unit file.

12) TheTool box and common shape box can be used to design HMI layout as shown at figure below

Figure of HMI Assembly unit layout with certain parameters.

4.2 5.0 5.1

PLC PROCEDURE RESULT & DISCUSSION HMI RESULT

The first objective of HMI assembly unit process has been achieved, however the other two objectives does not meet the requirement of this learning module. Several problems that occurred during the project development are such as:1. Trainees cannot create the communication of HMI between the system units of Assembly Unit with Display Unit (Master). 2. Trainees do not fully understand on how to use the MCGS software to design the HMI system because the information and reference given are limited. 3. Because of the lack information and references, the configuration to perform the communication between HMI and PLC also cannot be done. 4. Some equipment and software used for this module are malfunction. 6.0 7.0 CONCLUSION RECOMMENDATION

7.1

RECOMMENDATION FOR HMI

Some of prevention method needs to be considered for this HMI projects are:1. Provide a complete references or manual which easy to understand by trainees for this module. 2. Ensure the equipment and the systems are functioning before trainees can handle the material and equipment. 3. Use another of HMI software which is more friendly user.