2003 presentation24

PROJECT ONPROJECT ONAUTOMATION OF TRUTZSCHLER DRAW AUTOMATION OF TRUTZSCHLER DRAW

FRAME: 02 WITH B&R PLCFRAME: 02 WITH B&R PLC

INDUSTRY ORGANIZATION PROFILE • TRUMAC ENG. CO. PVT. LTD is joint venture between Trutzschler

group company, headquartered in GERMANY & ATE group of companies of INDIA.

• Trumac offers its customers a wide range of latest technologies machineries developed by trutzschler who are acknowledged world wide as pioneers in blow room & carding technology.

• Trumac product range includes modern blow room machines for opening & cleaning of cottons as well as synthetic fibers, dust remover equipment, waste removers installations, high production cards as well as control system .

• Trumac has grown from strength to strength ever since its inception in 1987 in A’bad(INDIA).

• Ties between Trumac & Trutzschler are at every level, ensuring that the best German working practices are transferred to Trumac.

• This is the reason why Trumac has established in Indian market for its blow room & high production cards .

• Several hundred blow room line & cards were supplied all over India & abroad.

ABOUT PROJECT

• This project is about Automation of Trutzschler Draw Frame 02 (TD-02)with B&R PLC.

• The machine which makes the strong sliver by twisting the number of thin cotton threads feeds from the cans of feed creel is called Draw Frame machine.

• The name of project comes from the name of company Trutzschler and its Draw Frame series 02.

• TD02 machine is a substitution of the conventional draw frame machine HSR1000 to reduce the cost.

• The Yarn material produced by HSR1000 is of higher cost which all the customers can’t afford.

• In order to reduce the cost of the fabric material to satisfy the customers in cost with almost same quality the machine TD 02 is used.

• TD02 has lower cost than HSR1000 because it uses less component compare to the HSR1000.

• Our main aim of project is to add Indian customer specific features & reduce the cost of TMS-2 system and NOM3 relay module which used in control panel by replacing B&R PLC.

3D VIEW OF TD02

SCHEMATIC BLOCK DIAGRAM OF CONTROL PANEL OF

COMPONENT LAYOUT OF CONTROL PANEL

1: TMS, Trutzschler micro-computer system2: Key switch for service mode3: Power supply servo module4: Rotary can plate drive servo module, SM105: Rotary sliver feed creel drive servo module, SM106: Delivery drive servo module, SM20

MICRO-COMPUTER SYSTEM

INPUT CONFIGURATION PORT:0&1INPUT APPLICATION RELATED COMPONENTS

E0.0 FUSE MONITERING FUSE F010,F030

E0.1 SAFETY LOOP O.K. NOM3 A200

E0.2 SAFETY EQUIPMENT OK NOM3 A200

E0.3 MOTOR PROTECTION SWITCH MPCB Q100,Q115,Q120,Q130

E0.4 EMERGENCY STOP SELECTION SWT S210,S250

E0.5 SAFETY LIMIT SWITCH PROTECTIVE HOODS SAFETY SWITCH S230,S240

E0.6 COMPRESSED AIR O.K CHANGE OVER CONTACT B5

E0.7 PRESSURE MONITORING,CENTRAL SUCTION CHANGE OVER CONTACT B570

E1.0 DRAFTING SYSTEM CLOSED SENSOR B436

E1.1

E1.2

E1.3 DRAFTING SYSTEM COVER CLOSED SAFETY SWITCH S450

E1.4 DRAFTING SYSTEM LAP 2-SENSOR A440,A441

E1.5 MONITORING O.K. SENSOR B431

E1.6 DELIVERY ROLLS O.K. SENSOR B433

E1.7 COILER PLATE AREA OK SENSOR B432

INPUT CONFIGURATION PORT:2&3

INPUT APPLICATION RELATED COMPONENTS

E2.0 NO SLIVER BREAK SENSOR B468,SENSOR B467

E2.1 NO SLIVER BREAK SENSOR B466

E2.2 NO SLIVER BREAK SENSOR B465

E2.3 NO SLIVER BREAK SENSOR B463,B462,B461,B464

E2.4 3WAY KEYBOARD START/THREADING STARTA 520

E2.5 3WAY KEYBOARD INCHING MODE TIP A520,TIP A510

E2.6 3WAY KEYBOARD START START 510

E2.7 3WAY KEYBOARD STOP STOP A520,STOP A510

E3.0 SERVICE SWITCH (SERVICE OFF) NOM3 A200

E3.1 EXTERNAL EMERGENCY STOP

E3.2

E3.3 TURNSTILE POSITION SENSOR B106

E3.4 CAN STOPPER EXTENDED SENSOR B131

E3.5 EMPTY CAN AVAILABLE SAFETY LIMIT SWITCH S110

E3.6 START CAN FEEDWAY DRIVE SAFETY LIMIT SWITCH S132

E3.7 CAN MAGAZINE IS FULL SAFETY LIMIT SWITCH B109

OUTPUT CONFIGURATION PORT:0&1

OUTPUT APPLICATION RELATED COMPONENTS

A0.0 ENABLING SAFETY EQUIPMENT SAFETY LIMIT SWITCH S230,S240

A0.1 ENABLING IMPULSE SAFETY EQUIPMENT NOM3 A200

A0.2

A0.3

A0.4 FLASH LAMP WARNING CC CHANGING FLASH LAMP YELLOW H581

A0.5 SIGNAL LAMP NORMAL MODE (GREEN) SIGNAL LAMP GREEN H580

A0.6 SIGNAL LAMP WARNING (YELLOW) SIGNAL LAMP YELLOW H580

A0.7 SIGNAL LAMP FAULT (RED) SIGNAL LAMP RED H580

A1.0

A1.1 LOAD DRAFTING SYSTEM SOLENOIED VALVE Y3

A1.2 THREAD WEB GUIDE SOLENOIED VALVE Y1

A1.3

A1.4 LOAD TOP ROLL (SLIVER CUT) SOLENOIED VALVE Y6

A1.5

A1.6

A1.7

OUTPUT CONFIGURATION PORT:2&3

OUTPUT APPLICATION RELATED COMPONENTS

A2.0 FAN IN FRAME CLOCKWISE RELAY K040

A2.1 FAN IN FRAME COUNTERCLOCKWISE RELAY K041

A2.2 CONTROL CABINET FAN RELAY K003

A2.3 SUCTION FAN ON RELAY K120

A2.4 SUCTION FLAP CENTRAL SUCTION SOLENOIED VALVE Y571

A2.5

A2.6

A2.7

A3.0

A3.1

A3.2

A3.3 TURNSTILE DRIVE CLOCKWISE RELAY K116,RELAY K115

A3.4 TURNSTILE DRIVE COUNTERCLOCKWISE RELAY K116,RELAY K115

A3.5 CAN STOPER EXTENDED SOLENOIED VALVE Y5

A3.6 CAN FEEDWAY DRIVE RELAY K130

A3.7

MODES OF OPERATION

Working mode• In working mode the machine does all the routine work for which it was

programmed . As the inputs are provided to the PLC the output is taken from it. There are basically 16 inputs & 16 outputs provided in the PLC. If

more are needed than we can also use the expansion module.• In this mode there are sensors which sense the inputs and provide them to

the PLC through which we can get the output. There are a total of nine sensors for doing the work.

• The basic function of the machine is to count, even & uncurl the raw slivers that are provided to the machine. The input slivers are provided to it from the carding machine which is used to take the dust out from the cotton.

• Multiple number of slivers are provided to the machine through the feed crill. All of these slivers are than compressed into one sliver by the drawing process. After this the slivers are carried out where they are stored in the

bucket in the form of output.

MODES OF OPERATIONService mode• Within the scope of servicing, the current condition & the functionality of

components are assessed. Whatever maintenance & repair work is necessary is determined from this condition.

• In this operating mode we can select & test individual components. In some cases additional information is seen, such as rotary speeds, connections or the corresponding sensors. We can activate the service mode through the B&R PLC

• Now for selecting the component to test we can select any of it by pressing the enter button on the PLC. The components which we can test are Motors M003, M004, M115, M120, and M130. Valves Y1, Y3/Y6, Y5, Y6, Y571. Sensors A460…A468, B431, B432, B433, B436, S110, S132, S230, S240, S450. L.E.D. RED, YELLOW, GREEN.

• All the defective components after the service mode are to be replaced by the new ones. The other components which are up to date should be cleaned perfectly. Then the machine should be fully assembled back as it was before. We can manually or automatically service the machine through the service mode.

PROGRAMMING FLOW GRAPH OF SERVICE MODE VIA B&R PLC

MAIN MENU FLOW GRAFH

VALVE TEST FLOW GRAFH

MOTOR TEST FLOW GRAFH

DRIVE TEST FLOW GRAFH

SENSOR TEST FLOW GRAFH

LED TEST FLOW GRAFH

HUMAN MACHINE INTERFACE

1. MODE SELECTION

MACHINE MODE SELECT 1 = Go for Working Mode

TD 02_MODE 0/1 0 = Go for Test Mode

WORKING/TEST=1/0

2. AUTO_MANUAL

TEST MODE 1 = Go for Auto mode TD 02_MODE

0/1 AUTO/MANUAL=1/0 0 = Manual Mode

3. GO TO0. MOTOR TEST 5.I/P STATUS F1 Auto_manual1. VALVE TEST 6.O/P SATUS2. DRIVE TEST 7. D & T3. SENSOR TES 8. RESTART F2 Auto_manual4. SPECIAL TES 9. WARNING

4. MOTOR SELECTION

MOTOR 003 F1 GO TOMOTOR 004MOTOR 115MOTOR 120MOTOR 130 F2 GO TO

5 .VALVE TEST

VALVE Y1 F1 GO TOVALVE Y3VALVE Y5VALVE Y6VALVE 571 F2 GO TO

6. SENSOR TEST

B132 S450 F1 GO TO B431 S110 B432 S230 B433 S240 B436 F2 GO TO

7. INPUT STATUS

I/P1 I/P6 F1 GO TO

I/P2 I/P7

I/P3 I/P8

I/P4 I/P9

I/P5 I/P10 F2 GO TO

8. OUTPUT STATUS

O/P 1 O/P 6 F1 Go TO

O/P 2 O/P 7

O/P 3 O/P 8

O/P 4 O/P 9

O/P 5 O/P 10 F2 GO TO

9. DATE & TIME

DATE DD/MM/YYYY F1 GO TO

**/**/****

TIME: HH/MM/SS

**/**/** F2 GO TO

11. RESTART MODE

*** Restart Mode *** F1 GO TO1. Restart Target : 02. Erase all Data and Restart Target : 0 F2 GO TO

To come out of hanging situation of LAP COMMANDER, Without Switching off the Main Switch , if you want to start the target then make Restart target = 1.

2nd is 1 then it will Erase all set parameters and retentive data. After it all the parameterization will be done again.

12. WARNING

MOTOR 003 F1 GO TO MOTOR 004MOTOR 115MOTOR 120MOTOR 130 F2 GO TO

B&R PROGRAMMING MODULES

B&R PROGRAMMING MODULES

Cyclic Program #1-[10ms]

• Input Initialization

• Output Initialization

• Variable Initialization

• Manual Mode Service Program

• Auto Mode Service Program

• Program for Working Mode

Cyclic program #2-[10ms]

• Program for warning

• Program for bitmap • Program for password • Program for reset

Cyclic program #3-[50ms]• Program for date and time • Program for key and led test

SIMULATOR OF CONTROL PANEL OF TD02

BLOCK DIAGRAM OF SIMULATOR

Power Supply

RelaysPower Terminal

Switch Mode Power Supply

MCBPower Motor Protection

Circuit BreakerPLCOutput Lamps

Input Push ButtonsPower Switch

Input Port

Output PortPo

wer

Su

pply MCB Contactor

INTERNAL VIEW OF SIMULATOR

DIGITAL I/P ASSIGNMENTTerminal No. Address Description

01 - (0V DC)

02 + (24V DC)

03 I1 Not used

04 I2 To start sensor B431

05 I3 To start sensor B432

06 I4 To start sensor B433

07 I5 To start sensor B436

08 I6 To start sensor s110

09 I7 To start sensor s230

10 I8 To start sensor s240

11 I9 To start sensor s450

12 I10 To select Auto/manual

13 I11 Warning in M130

14 I12 Not used

15 I13 Not used

16 I14 Not used

17 I15 Not used

18 I16

DIGITAL O/P ASSIGNMENT

Terminal No. Address Description

01 - (0V DC)

02 + (24V DC)

03 Q1 To Start M003

04 Q2 To Start M004

05 Q3 To Start M115

06 Q4 To Start M120

07 Q5 To Start M130

08 Q6 To Start Y571

09 Q7 To Start Y6

10 Q8 To Start Y5

11 Q9 To Start Y3

12 Q10 To Start Y1

13 Q11 To Indicate ERROR

14 Q12 To Indicate WARNING

15 Q13 To Indicate RUNNING

16 Q14

17 Q15

18 Q16

SCHEMETIC DIAGRAM OF SIMULATOR

3 PHASE MOTOR INTERFACING

SINGLE PHASE MOTOR INTERFACING

PLC O/P TO RELAY INTERFACING

SENSOR TO I/P INTERFACING

APPLICATION• Machine TD02 has two mode of programming Working mode and Service

mode in working mode machine automatically sense the drive position and material status and these information is given to the PLC and according to the input condition and machine working PLC operate motors, drives and valves when in Service mode there are two mode Manual mode and Auto mode.

• In Manual mode we have to independently select each and every motor, drive, sensor, valve and lamp start them and stop them after noting the information about whether it working properly or not. If not then maintenance is require for the machine.

• In Auto mode machine Automatically select each and every motor ,drive,sensor,valve and lamp start them and stop them to note the information about whether it work properly or not. If maintenance is require then go to maintenance mode of machine.

• We here replace microcomputer system and NOM3 module from the Control panel of the TD02 with the B&R PLC and program it to work same as microcomputer system and NOM3 module to save cost of up to 1.25 lakh. Rs.