điều khiển thích nghi theo mô hình mẫu

1

LI M U

Lch s ra i ca cng ngh sn xut giy c my nghn nm

trc do ngi Trung Quc pht minh ra. Tri qua my nghn nm pht trin

ca cng nghip sn xut giy, v c bn quy trnh lm ra mt t giy khng

thay i l my nhng thit b, my mc sn xut giy th pht trin khng

ngng theo cng cng nghip ch to my.

Trc y kch thc kh giy lm ra b gii hn nh, chng loi giy

t, ngy nay vi cc thit b my mc hin i con ngi c th to ra rt

nhiu chng loi giy t giy bo, giy vit, giy bao b..v.v. cn v kch

thc kh giy xeo c giy vi kh rng 8 m chiu di khng hn ch

v trng trn 90 ISO (n v o trng ca giy).

Sau khi xeo giy vi kch thc kh ln, to thnh giy thnh

phm tu thuc vo cng nng s dng m ngi phi ct giy thnh nhng

kh giy c kch thc ph hp v d nh sch v v.v.

to ra nng sut lao ng cao v kch thc kh giy chnh xc (vi

chnh xc nh hn 1mm ngi ta ch to ra my ct giy. Vi t cch l

mt sinh vin hc ngnh in cng nghip v dn dng ca trng i hc dn

lp Hi Phng, em l Phm Trung Dng sinh vin lp DCL201 kho 2008-

2010 c giao n tt nghip vi ti Nghin cu tm hiu h thng

my ct giy trong nh my giy HAPACO. i su ci tin quy trnh ct

giy bng PLC do Thc s Nguyn on Phong hng dn thc hin

Ni dung ti gm 4 chng:

Chng 1: Tng quan v cng ngh sn xut giy

Chng 2: Tng quan v dy chuyn v kt cu c kh ca my ct giy XII.

Chng 3: S nguyn l mch iu khin, mch ng lc, nguyn

l hot ng b phn bn c.

Chng 4: S mch ng lc, iu khin cho b phn dao ct giy

dng PLC

2

Chng 1

TNG QUAN V CNG NGH SN XUT GIY

1.1 Gii thiu tng quan v cng ty cp hapaco

* Nhng im mc ng nh

3-2-1960

- Cng ty CP HAPACO ra i t s tip nhn X nghip Giy ba ng

Tin - mt doanh nghip Nh nc ang bn b vc ph sn,vi c s vt

cht ngho nn lc hu, trnh lao ng thp km,ch sn xut mt loi giy

ba, vi sn lng 700 tn/ nm.

Nm 1986

- Tri qua nhiu bc thng trm v nhiu ln sp nhp, X nghip sn

xut Giy ba c i tn thnh Nh my Giy Hi Phng.

Nm 1992

- Nh my Giy Hi Phng chuyn thnh Cng ty Giy Hi Phng-

HAPACO. L Doanh nghip u tin ca Hi Phng xut khu hng sang i

Loan, thc hin thnh cng chnh sch m ca th trng khu vc 2 ( cc

nc t bn) ca ng v Nh nc.

1994- 1997

- Cng ty Giy Hi Phng a 6 dy chuyn thit b sn xut giy ln

tnh Yn Bi, thnh lp n v lin doanh : Cng tyTNHH Hi Yn v X

nghip giy xut khu yn Sn cng sut 6.000 tn/nm.

Nm 1998

- Cng ty Giy Hi Phng tch mt b phn gm 3 phn xng tin

hnh c phn ho th im thnh lp Cng ty c phn Hi u - Theo Ngh

nh 28/ CP ca Chnh ph, l Cng ty u tin ca Hi Phng thc hin

thnh cng c phn ho doanh nghip Nh nc.

3

Nm 1999

- Cng ty Giy Hi Phng hp nht vi Cng ty c phn Hi u , i tn

thnh Cng ty c phn Giy Hi Phng .

Nm 2000

- Thng 8/2000, HAPACO nim yt c phiu trn th trng chng

khon Vit Nam- l 1 trong 3 n v u tin m ca th trng chng khon

Vit Nam ti Trung tm Giao dch chng khon Tp H Ch Minh, nay l S

Giao dch chng khon Tp H Ch Minh.

Nm 2001

- Thng 9/2001, HAPACO u t 2 dy chuyn thit b sn xut giy

ln tnh Lo Cai thnh lp X nghip Lin doanh HAPACO - Vn Bn, tnh

Lo Cai

Nm 2002

- HAPACO pht hnh thnh cng 1 triu c phiu, nng tng s c phiu

ca HAPACO trn sn ln hn 2 triu c phiu giao dch. L n v u tin

ca th trng chng khon pht hnh c phiu t u thnh cng c 32 t

VND, p ng kp thi nhu cu pht trin sn xut- kinh doanh.

Nm 2003

- Ngy 23/11/2003, HAPACO khnh thnh Nh my bt giy Ho Bnh

cng sut 6.000 tn/ nm, ti x Vn Mai, huyn Mai Chu, tnh Ho Bnh.

Nm 2004

- Ngy 23/11/2004, UBCKNN cp Giy chng nhn ng k pht hnh

s 06/UBCK-KPH cho HAPACO pht hnh thm 1.242.251 c phiu , nng

tng s c phiu ca HAPACO ln 3.250.251 c phiu giao dch.

Nm 2006

- Ngy 16/04/2006, HAPACO khnh thnh Nh my giy Kraft giai

on 1, cng sut 22.000 tn / nm, ti x i Bn, huyn An Dng,Tp Hi

Phng - y l Cng trnh trng im ca Tp Hi Phng cho mng i hi

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ton quc ln th X ng Cng sn Vit Nam.

Nm 2007

- Ngy 28/11/2007, c phiu HAP tip tc c a thm vo giao dch,

nng tng s c phiu trn sn ca HAPACO ln gn 15 triu c phiu giao

dch. Nm HAPACO c nhiu thnh tch, hiu qu kinh t cao trong lnh vc

ti chnh, chng khon, t li nhun hn 73 t ng.

- Ngy 19/5/2007, HAPACO khnh thnh Nh my bt giy Hi H trc

thuc Cng ty c phn Hi H ( n v thnh vin ca HAPACO) giai on 1,

cng sut 12.000 tn/ nm, ti huyn Bc Quang, tnh H Giang.

Nm 2008

- HAPACO k nim 10 nm c phn ho. Cng ty c Ch tch nc

tng Hun chng c lp hng ba ; Tng Gim c - TS. V Dng Hin

c tng Hun chng Lao ng hng nht.

- Khi mi c phn ho , vn iu l ca Cng ty l 1,25 t ng, n u

nm 2008 vn iu l ca Cng ty c nng ln 500 t ng.

Nm 2009

- 2/2009, c phiu HAP tip tc c a thm vo giao dch 2.192.369

c phiu, nng s c phiu trn sn ca HAPACO ln gn 17 triu c phiu

giao dch.

- Ngy 8/8/2009, Cng ty c phn HAPACO c i tn thnh Cng ty

c phn Tp on HAPACO ( tn giao dch l: Tp on Hapaco), gm 14

n v thnh vin ; v 4 n v lin kt.

- Ngy 13/5/2009, khi cng xy dng Bnh vin Ph sn Quc t, ti s

738, ng Nguyn Vn Linh, qun L Chn, Hi Phng.

- Ngy 16/8/2009, t chc l ng th Khu cng nghip Nam nh V,

din tch 646 ha. L mt trong nhng D n trng im ca Tp Hi Phng v

min Bc.

- Ngy 2/9/2009, Cng ty HAPACO Hi u vinh d c tng Danh

5

hiu Sao Vng t Vit.

- Ngy 8/9/2009, Tp on HAPACO chnh thc c cp Giy php

thnh lp Cng ty TNHH HAPACO ti B - la - rt.

-Ngy 16/10/2009, Tp on Hapaco t chc khai trng CTy

I.T.Hapaco ti TP Minsk- Th Cng ha Belarus.

- Ngy 25/11/2009,Tp on HAPACO t chc khai trng Cng ty

TNHH quc t lin hp Trung- Vit, ti s 99, ng Gio Nhn, khu Tam

Dn, TP Cao Hng ( i Loan).

- CNG TY C PHN HAPACO PHNG NG l cng ty chuyn

sn xut giy xut khu cho i Loan, sn lng hng nm khong 10000

tn/nm.

1.2 Quy trnh cng ngh chung sn xut giy

Ti cng ty, sn phm c sn xut ra l:

Ba cctng trng: Cyber XLPac, Art Maestro, Pearl Graphik,

Ecoviron,...

Giy/Ba cctng trng bng : c th l Indolux Safire, Giy Indolux,

Nhn

Indolux

Ba cctng chuyn dng: c th l Carte Persona, Cupstock Base, Ba

cctng trng PE.

Giy: giy vit v giy in, giy p phch MG

Nguyn liu th dng cho sn xut l cc loi c ngun gc t g: Tre, Bch

n, phi lao, g cng tng hp v si ti sinh: giy loi.

Ton b quy trnh sn xut ca nh my c chia thnh:

Quy trnh to bt

Quy trnh lm giy

6

Quy trnh to bt: Qu trnh to bt bao gm chun b nguyn liu th,

nu, ty ra. Cng vic ny c thc hin cc b phn khc nhau nh

c miu t di y:

Bm/Nu: Nguyn liu th nh tre, bch n, phi lao, g sibabul c

ra bng nc, sau c bm ti xng bm. Dm g hn hp sau

c em cn v cho vo my nu x l theo m. Sau , mt lng nc

trng v nc en ph hp (ph thuc vo tng lng kim hot tnh v tng

kim) c cho vo my nu v duy tr dung t theo t l 1: 2,75. Dung

dch cp c gia nhit s b bng hi gin tip. Qu trnh nu ko di trong

2,5 gi c s tham gia ca hi trc tip. Bt giy c nu sau c thi

xung bnh thi, ti y bt giy c lm long bng nc en; sau c

bm vo b LC lm long tip.

To si mi: Bt giy lm long sau c ty ra bng cng

ngh to si mi. y l h thng phc tp hn s dng lng nc ti thiu

ty v ra bt. Nc nng c s dng nhm nng cao hiu sut ty ra.

Quy trnh ty Khng s dng nguyn t Clo (ECF) c s dng nhm lm

gim mc to AOX. Quy trnh ty ECF s dng phng php kh lignin

bng xy, sau l ty ClO2, chit oxy v ty ClO2.

X l si th cp mi: Ngoi bt giy nguyn cht, si ti sinh cng

c s dng lm ba cc tng. Giy loi c nghin thnh bt trong my

nghin bt gin on hoc my nghin bt lin tc, lm sch bng my lm

sch cng cao, sau lm sch tip bng my lm sch ly tm, ri c

c c v chuyn qua my phn tn nng phn b ng u cc ht. Ngoi

ra, c th s dng bt g mm nhp khu.

Xeo giy: Lm giy tun theo cc bc truyn thng: sng, lm sch

v hnh thnh giy (l li), p, sy. C 4 loi my xeo dng sn xut

cc loi giy v ba cctng khc nhau. Cc loi my ny c trnh by

nh di y:

7

My xeo 1: y l loi my kt hp c kh nng sn xut cc loi sn

phm MG/MF p st, cc loi sn phm mt lp/a lp. Ba cctng p st

hai lp, ba lp (ba cctng ng gi cht lng) v giy Kraft c sn xut

bng my ny.

My xeo 2: y l loi my a nng MF vi my cn h & cc b phn

cn trng v b phn kim sot dy ca giy.

My xeo 3: y l my giy Yankee loi nh s dng sn xut cc

loi giy p phch dng cho mc ch bao gi v ng gi.

My xeo 4: y l loi my hin i c li th cnh tranh ton cu v

cht lng, tnh kinh t v quy m sn xut v chi ph. Ba hp gp, ba

SBS, ba WLC, ba ng gi cht lng c sn xut bng loi my ny. Chi

tit my: 3 lp, cu hnh 4 li, ng knh MG 6,5 m, 3 trm trng, DCS &

QCS: 5 my tnh thong minh nhm cung cp phn hi v kim sot trc

tuyn.

Ba cc tng bao gm nhiu lp. Lp trn cng c lm bng bt giy

nguyn cht c ty sch. Lp th hai c lm bng bt giy ti sn

xut t giy loi trong quy trnh lm giy. Lp gia v lp cui c lm

bng bt si th cp (NSFT). Cc lp cui cng c x l ho hc bng keo

ha cht. Cc bc chnh c lin quan l : tinh lc, trn vi h ha cht, phn

...trong trng hp ca lp trn cng v lp di cng, sau l lm sch ly

tm, lm sch bng sng p lc.

Bt giy lm sch c a vo hm phun bt, t y c chuyn n

l li di trong trng hp ca lp trn cng v sau chuyn n l hnh

thnh giy (kt cu hnh tr s dng ht chn khng) S hnh thnh t giy

din ra trong l li/nh hnh. m d c loi b l p v cui cng

giy c lm kh qua mt chui cc my sy. Quy trnh sn xut giy vit

v giy in tng t nh nh quy trnh hnh thnh mt lp giy n trong sn

xut ba cc tng.

8

Giy loi t my giy c ti sinh thng qua B nc m, B Tn thu

Si Mi (NFRT) hoc mng gom du, vv.

Ngoi cc bc x l chnh, cn c mt s c cc b phn ph ch yu tn

thu v ti sinh/ti s dng giy loi to ra trong qu trnh sn xut. Cc b

phn ny bao gm:

Nh my sn xut tm bt

Nh my ClO2 v O3

Nh my tn thu x a, My kim ha v l vi

Dy chuyn sn xut bt giy ca Nht t nguyn liu phi g gm:

1. My nghin tinh hai a DDR, vi hai b lm tinh mang n nng sut

cao gp 2 ln trn cng 1 loi chn my c th gim ti a mc ma st

v tip xc gia cc b phn kim loi xy ra trong nhng hot ng ti nng.

2. My lc bt giy gip loi b tp cht mt cch nhanh nht.

3. My lc th cp (x l phn b loi) cho kt qu sng lc tt hn hiu

qu gp 4-5 ln so vi my sng rung truyn thng. Thit b ny tng i

gn nh v c chng nhn l ti thiu nhim khu vc hot ng.

4. My lm sch nng cao c kh nng loi b cc tt kim loi, ct v

nhng tp cht khc trong bt giy. Ngoi ra, n cn gip cho vic lin tc

loi b nhng vt l ngay c vi mt lng nc cn bng lm sch ti

thiu. c bit, vi thit k phn x cui gip loi b ngay c nhng ht ct

nh nht nng l 1.0-1.5%

5. My nghin chnh c thit k gip cho vic bo tn nng lng,

m bo hiu qu nghin v tit kim chi ph trong sn xut vi kh nng

nghin nguyn liu cp thp m khng lm hng si bt.

6. My lc dng trng gip ko di thi gian lu bt bn trong v nng

bt ra n nh khin qu tnh x l bt khng b dnh li do nng bt

u ra khng nh hng n bt

9

1.3 Quy trnh cng ngh sn xut giy t b ma

M hnh nh my sn xut bt giy di dng bt thng phm hoc m

hnh nh my lin hp bt giy v giy, sn xut giy in bo, giy in v giy

vit. Gii php tt nht l xy dng ng thi nh my bt giy v giy sn

xut giy in bo, giy in & vit.

Cng sut c th a dng t 50 n 250 tn/ngy v khng yu cu mt

thit b c bit no.

Cng sut bt ty trng c th t c l 250 tn/ngy.

D liu nh my m hnh 50.000-100.000 tn/nm

1. Sn phm: Giy in bo, giy vit v giy in

2. Cng sut my xeo: 50-100.000 tn/nm tnh theo nh lng giy

in bo 45g/m2

3. Thnh phn x si:

i vi giy in bo: Bt Ho C (CMP) hoc Ho Nhit C

ty trng (CTMP)t b ma: 40-55%

Bt ho ty trng t b ma: 35-40%

Bt g ty trng (Bt ho, hoc bt CTMP

hoc bt mi): 15-25%

Cht n 0-8%

i vi giy in v giy

vit:

Bt ho ty trng t b ma: 70-80%

Bt ty trng si di (NSBK): 10-30%

Cht n: 10-20%

4. Cc Khu vc ca nh my Phn xng Chun b nguyn liu b ma

Phn xng Sn xut bt Ho C

Phn xng Sn xut bt Ho

Phn xng ng lc

Phn xng Thu hi Ho cht

10

Trm Cung cp v X l nc thi

Phng Th nghim

Phn xng Bo dng

Cc cng trnh Ph tr khc

Dy chuyn sn xut bt ho

ty trng t b ma bao gm:

H thng nu lin tc kiu PANIDA

H thng Ra bt nu

H thng Sng bt nu

Tch loi lignin bng xy

Ty trng 3 giai on (D - EO - D)

H thng chun b ho cht

C TRNG NGUYN LIU TH-THNH PHN HO HC

B ma c s dng trong nh my bt phn ln l c kh tu v

c bo qun bng phng php t (dng h thng phun ma hoc ao h).

Vic phn tch b ma c tin hnh sau cc giai on bo qun khc nhau

v cho gi tr trung bnh nh sau:

S liu Phn tch B ma kh tu:

Thnh phn Ho tan trong nc lnh % 3,49

Thnh phn Ho tan trong nc nng % 5,95

Thnh phn Ho tan trong Ru cn -benzene % 3,112

Thnh phn ho tan trong NaOH % 38,08

Hm lng Lignin 20,26

Hm lng Pentozan % 30,661

trng % 32,00

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CHT LNG BT HO TY TRNG T NGUYN LIU B MA

Mc tiu ca nh my sn xut bt ho ty trng t nguyn liu b ma

l t c cht lng nh sau:

Tnh cht quang hc Tnh cht l hc ti

30oSR

c % 75 Ch s bn ko Nm/g 60

H t tn x nh sng m2/kg 20 Ch s bn x mNm2/g 4,7

trng % ISO 85 Ch s bc kPam2/g 3,5

H THNG CNG NGH LA CHN

H thng nu bt kraft

Loi thit b thch hp nht nu bt kraft t b ma v cc loi nguyn

liu phi g khc l h thng nu bt lin tc Kiu PANDIA.

Thit b chnh:

H thng PANDIA c la chn cho m hnh nh my ny bao gm

cc thit b chnh sau:

Phu np liu kiu l quay - Type PDF-110

Vt ti - Type EQ1000

Vt np liu -Type SF26

Bung tip nhn nguyn liu (ca nguyn liu vo ni nu) -Type

IC42-30

Ni nu dng ng -Type DIG 72-40

Van x bt Type CBC -42 v DIS42

Thng s cng ngh:

Thi gian nu: 10-15 pht

Nhit nu: 160-170oC

Hiu sut bt sau nu: 50-52%

T l Na2O: 11% so vi NL KT

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sunfua: 20%

Nhit x bt: 95oC

H thng ra v sng bt nu:

Qu trnh ra c thc hin 3 cp trong thit b thng ra chn khng

hin i, vn hnh bng h thng iu khin. H thng sng c lp t gia

giai on ra 2 v giai on ra 3.

Thit b chnh:

Thit b lc ct nng cao (HD Cleaner)

Thng ra chn khng, ng knh 4.0 m x 7.5 m (Type CORU-

DEK)

Thit b Sng giai on u (2 cp- type 212H-H1-Q)

Thit b Sng giai on 2 (1 cp- Type 2080H-H1-Q)

Thit b Sng giai on 3 (sng rung)

H thng Thit b lc ct 2 giai on

Thng s cng ngh:

Nng bt trc ra: 1,2%

Nng bt sau ra: 12 %

tn tht bt sau sng: 1,5%

Nng bt vo:

Ra: 1,2%

Sng giai on 1: 2,5%

Sng giai on 2: 1,2%

Sng rung: 1,0%

Lc ct giai on1: 1,0%

Lc ct giai on 2: 0,5%

Tch loi lignin bng xy -kim:

Cng ngh tch loi lignin bng xy thc hin ti nng trung bnh

MC cng vi h thng thng ra chn khng ba cp hin i, vn hnh bng

13

h thng iu khin.

Thit b chnh:

Bm bt nng trung bnh MC t h thng ra v sng

Thit b trn tc cao, Type 600

Thp phn ng xy cng vi van x

Thng ra chn khng, Type CORU-DEK, ng knh 4.0mx 7.5

m

Thng s cng ngh:

Tn tht sau qu trnh xy: 3,0%

Kappa bt vo: 14

Kappa bt ra: 8

Thi gian lu: 60 pht

Nhit : 95oC

Mc dng xy: 14kg/tn bt kh gi

Mc dng kim: 15kg/tn bt kh gi

Ty trng:

H thng ty trng c thit k theo cng ngh ECF bao gm 3 giai

on: D0-EO-D1

Thit b chnh:

Bm bt nng trung bnh

Thit b phi trn ba pha (phi trn ClO2 vi bt)

Thit b phi trn xy

Thp ty (3 giai on)

Thng ra chn khng (3 giai on) Type CORU-DEK, ng knh

4.0mx 7.0 m

Thng s cng ngh

trng cui cng: 85-86% ISO

14

Thng s cc giai on:

Giai on ty D0 E/O D1

Ho cht dng kg/BDMT kg/BDMT kg/BDMT

ClO2 tnh theo clo hot tnh 23 - 16

Na2O - 16 -

xy - 5 -

SO2 - - 3-5

H2SO4 10 - 5

Nhit , oC 55 70-80 75-85

Thi gian lu, pht 60 15/75 240

X l mi trng:

Cng ngh x l cc cht thi, c bit l nc thi an ton tuyt i i

vi mi trng, m bo tiu chun i vi cc ch s COD, BOD, SS, mu

Pt-Co v AOX

Cng ngh:

Cng ngh ho l

Cng ngh sinh hc (hiu kh hoc k kh)

Thit b:

Thit b x l lng lc v tuyn ni

Thit b x l ho hc

Thit b x l sinh hc hiu kh v k kh

H sinh hc

CC NH CUNG CP TIM NNG:

Metso

Andritz

GL&V v cc cng ty khc

15

Voith

Allimand v cc cng ty khc

SUT U T:

Chi ph thit b cho nh my giy v bt giy xp x 1.200 EUR/tn

giy (thit b chu u).

Sut u t cho xy dng nh my bt giy v giy xp x 1.500

EUR/tn giy (Thit b chu u).

Chi ph u t cho nhng d n m hnh ny cn ty thuc cch m

chng ta chn la tin hnh u t xy dng nh my.

Chi ph cao nht s do vic yu cu xy dng nh my v do nh

cung cp quyt nh,

Chi ph thp nht c th c nu Vin ca chng ti thc hin mt s

ni dung t vn nh nu trong bn cho ny.

1.4 Mt s ch tiu kinh t

D tho Phng php lun S dng Nng lng Hiu qu ti Cng ty

c s dng lm c s nh gi nh my nhm xc nh v thc thi cc gii

php gim thiu nng lng, nguyn liu v cht thi. Sau y l mt vi kinh

nghim b ch:

Nhim v 1b Thnh lp i v thng bo cho nhn vin

Cng ty c mt Gim c Nng lng nhit tnh v mt s nhm lm

vic nh hot ng trong lnh vc bo tn nng lng v ti nguyn ti cc

phng ban khc nhau trong cng ty. Vai tr, trch nhim v quyn lc ca h

rt r rng v c ban hnh thnh vn bn. Tuy nhin, cc nhm lm vic

trong lnh vc bo tn nng lng v ti nguyn hot ng trn c s c

lp v gia h c rt t s ng vn. i c thnh lp bao gm Gim c

Nng lng v mt s thnh vin t mi nhm lm vic nhm xem xt vic

qun l nng lng cp cng ty.

16

Bi hc kinh nghim: Vic sng lp i vi cc i in t cc nhm

lm vic hin c khc nhau l mt tng hay v bng cch cng vic ca

cc nhm ny s c lin kt vi nhau.

Nhim v 1d La chn khu vc trong tm

K t khi cng ty thc hin quan trc nh k v thu thp d liu, cng

ty bit c ni pht sinh cc vn chnh v nng lng cng nh lnh vc

no cn ci tin V th, la chn khu vc trng im l tng i d dng.

Tuy nhin, cn c vo s liu o c v phn tch d liu thm ca i, mt

s khu vc trng im c b sung. Cc khu vc trng im c la

chn l ni hi tn thu soda, l vi, ni nu, my xeo v ni hi tng si t

bng than .

Bi hc kinh nghim: H thng quan trc v thu thp s liu tt gip

cng ty xc nh cc khu vc trng im nhng vn cn tin hnh cc o c

b sung tm ra bt c khu vc trng im no km r rng.

Nhim v 2b Lp s quy trnh cng ngh khu vc trng tm

Cng ty l nh my giy ln kt hp. Do , s t chc sn xut

khng c v cho ton b nh my, m ch dnh cho cc khu vc trng im

c la chn.

Bi hc kinh nghim: iu chnh bn v s quy trnh cng ngh ph

thuc vo quy m v phc tp ca cng ty.

Nhim v 2d nh lng u vo v u ra, v chi ph xc

nh s liu nn

Cng ty t nh lng hu ht u vo v u ra ch yu v cc thng s

vn hnh. Cc s liu c ghi chp nh k v c sn trn mng intranet ca

cng ty. V th, vic phn tch xu hng tiu th ti nguyn bng my mc v

so snh vi s liu chun khng gy nhiu kh khn cho i.

Bi hc kinh nghim: Tip cn c bt k d liu in t no sn c

s y nhanh qu trnh thu thp d liu cho i.

17

Nhim v 4c: Lp xut thc thi v quan trc ban lnh o

ph duyt

Vn khng phi l lm cch no ban lnh o cp cao ph duyt v

cng ty quy nh r rng v vn ph duyt v thc thi gii php . Nhng

tiu ch nh gi quan trng nht l:

Chi ph u t: Nhng d n i hi u t di 10.000 USD c

Ph Gim c Nh my ph duyt. Nhng d n trn 10.000 USD c

U ban Qun l B phn ti tr s chnh kim tra v ph duyt. Trn thc t,

trong nhng nm gn y cc d n s dng nng lng hiu qu ln ti

40.000 USD lun c ph duyt m khng xy ra qu nhiu vn .

Thi gian hon vn. Nhng gii php c thi gian hon vn hn ba nm

s phi chu nh gi ti chnh chi tit hn trc khi a ra quyt nh c thc

thi hay khng.

nh hng ti quy trnh sn xut: Nu nh thc thi gii php cn

ngng sn xut hoc lm cho sn xut b gin on th cn t k hoch thc

thi ng thi vi hot ng bo dng nh k, c th l t k hoch ngmg

sn xut hoc i tu tng th nh my.

Bi hc kinh nghim: Quy trnh xin ph duyt t pha ban lnh o s

thong sut hn nu nh cng ty c nhng quy nh r rng v vic ph duyt

v thc thi gii php.

Bc 6 Ci thin lin tc

Cng ty t ra mc tiu gim 2% tiu th nng lng ring mi nm v

cng ang d kin ci t phn mm cn thit nhm phn tch d liu trc

tuyn, gm: Xc nh li, rung chung bo nu c vn g sai st, tnh ton chi

ph v khon tit kim , phn tch xu hng tiu th ti nguyn,vv. H thng

cng c thit k nhm a ra mc tiu hng nm cho tiu th nguyn liu

v nng lng ti mi b phn.

Bi hc kinh nghim: Ci t cc chng trnh phn mm c th l mt

18

cch tt cng ty c th theo di tt hn hin trng nng lng.

GII PHP

Cc gii php c xc nh theo 2 giai on. Tng cng, c 36 gii php.

Tn thu hi tc thi, Ni hi FBC/ Gim cht khng chy trong tro,

Tng din tch khu vc truyn nhit, Ci tin h thng nh sng.

Nm 2003, cng ty xc nh c 9 gii php. Trong s , 4 gii php

c thc hin, nm gii php cn li hin vn cha c thc hin.

Trong nm 2004, bn thn cng ty xc nh v thc hin 27 gii

php SXSHSDNLHQ m khng c s gip ca cc chuyn gia t vn bn

ngoi.

Cc gii php thc hin nm 2003 gip cng ty tit kim c

550.832 USD

so vi 6 thng trng im.

Thc hin cc gii php ny cng gip cng ty tit kim c 15481

tn than, nhng tiu th in tng ln 197600 kWh. Mc gim GHG thc ln

ti 23518 tn/nm.

Cc gii php thc hin nm 2004 gip cng ty tit kim c

725.383 USD so vi vn u t ban u l 289.987 USD vi thi gian hon

vn gin n khong 5 thng. Thc hin cc gii php trn cng gip cng ty

gim c 23418 tn GHG v tit kim ti nguyn c 12639 tn than/nm

v 3722720 kWh in. Ngoi ra, cng ty cng tit kim c 0,736 triu m3

nc mi nm.

Tng cng, vi vn u t 530.445 USD tit kim c 12.76.215

USD vi thi gian hon vn gin n khong 5 thng. Ngoi ra, cng ty cng

tit kim c 28120 tn than v 3525120 kWh in tng ng gim c

46666 tn GHG. Lng gim thiu ny chim khong 3,5 % mc gim pht

thi GHG ti cng ty.

19

Chng 2:

TNG QUAN V DY TRUYN V KT CU C KH

CA MY CT GIY XII

2.1 Gii thiu chung v cu to chc nng s dng ca my ct giy bp c XII

My ct giy bp c XII l mt thit b ct giy do i Loan sn xut, n

c th ct t kh giy c kch thc ti a 900 x 1000 mm thnh nhng kh

giy c kch thc nh hn, kh giy nh nht c th ct c c kch thc

50 x 50 mm. Chiu dy tp giy ti a l 200 mm

Cc ch s k thut:

- Trng lng 2000 kg

- Kch thc: di x rng x cao = 2.000 x 2.000 x 1.800 mm

- Cng sut 7 kW

- in p: 3pha 380V

Bao gm:

- 2 ng c 2kW 380VAC, 3 pha (1 ng c bt thn sau my ko

bnh lai dao ct. 1 ng c bt bnh thy lc bm du cho piston thy

lc chuyn ng ln xung.

- 1 ng c 0,75 kW max180 VDC, 1 pha (bt di mt bn chnh

lai bn c).

- 1 b ly hp 110VDC

V ngun 220 VAC cp in cho b phn iu khin trung Tm.

20

2.2 Cc bn v c kh minh ha chc nng ca cc chi tit my

12

1

11

10

9 6

4

5

3

2

7

8

Hnh 2.1 Tng th my ct giy bp c XII

1. xilanh thy thc

2. Mn hnh computer

3. Bn phm iu khin

4. Capo bo v bnh

5. Thn trc my

6. R le hnh trnh o chiu p

7. C

8. T in

9. Chn my

10. Mt bn ph

11. Nt iu khin

12. ng thy lc

21

Hnh 2.2 Thn trc my

Chc nng:

Thn trc my v thn sau my to thnh 2 vch kp sn g dao

chuyn ng gia 2 vch ny.

Thn trc my c hc cha cc r le v panel iu khin, trn

c gn cc nt iu khin v b iu khin trung tm iu khin ng c lai

bn c.

Hnh 2.3 Thn sau my

Chc nng:

Thn sau my c bt vo chn my v lin kt vi thn trc my

thng qua trc lch tm.

To vi thn trc my thnh 2 vch trt.

Ngoi ra thn sau my cn l x lun pitong ca h thng thy lc,

trn n cn c l ren bt xilanh thy lc.

22

Hnh 2.5 Hnh v minh ha hot ng ca dao ct v p

Dao v tr im cht trn

Chc nng

Tay bin v trc khuu bin chuyn ng quay ca trc hp s thnh

chuyn ng tnh tin ca sn g dao ct v iu chnh cao thp ca

dao khi dao nh dn qua cc qu trnh mi dao.

Hnh 2.6 Hnh v minh ha hot ng ca dao ct v p

Dao v tr im cht di

23

Hnh 2.7 Bc dn hng v trc lch tm

Chc nng:

Bc dn hng dn hng cho chuyn ng ca sn g dao ct

Trc lch Tm xuyn qua bc dn hng nh v bc dn hng v

iu chnh thng bng ca dao ct.

Hnh 2.8 Sn g dao ct

Chc nng: g dao ct giy

24

Hnh 2.9 Mt bn ct v mt chn bn c

Chc nng:

Mt bn chnh: tp giy khi ct

Mt chn c: Quy nh kch thc.

Hnh 2.10 B truyn ng

Chc nng:

Bin i chuyn ng quay ca ng c lai bn c thnh chuyn ng

tnh tin ca mt chn bn c qui nh kch thc ca tp giy ct v phn hi

kch thc thc t v b iu khin trung Tm thng qua Encorder.

25

Hnh 2.4 Chn my

Chc nng:

Chn my thn my v c gn xung my ( b tong) bng

cc bu- lng. Chn my c thanh ging lin kt 2 chn my v chu ti

trng khi v dao ct hot ng.

Hnh 2.11 B phn bm thy lc

Cu to:

B phn bm thy lc gm:

26

1. ng c bm (bm bnh rng n

khp ngoi)

2. Van iu khin 4 ca 3 v tr

3. B phn iu khin p lc du v

ng h ch p sut du

4. Bnh cha du thy lc, dung tch

50 lt

27

Chc nng:

Bm p lc du piston thy lc chuyn ng ln xung.

CHNG 3

S NGUYN L MCH IU KHIN, MCH NG

LC, NGUYN L HOT NG B PHN BN C

3.1 S nguyn l mch iu khin

Hnh 3.1 Cc phm trn b iu khin trung Tm

Hin th bng LED 7 thanh

KCH THC TH T BC M CT

7 8 9 M

ct

4 5 6 S bc

1 2 3 n v

kch thc

0

Tin

Li T ng

Start

Stop

28

29

22 18 20 X 22 23 25 18 X X 18 26

2 X 3 18 A B X X 16 30 3419

Nt nhy b-c

Computer

Ercorder220VAC

R2Li

R3

Tin

R5

Phanh

R4

Ngun /p

cao thp

R1

Ngun

12VDC

C/tc k/ch hnh trnh Bn c pha sau

2120

18

25

26

2324

C/tc k/ch hnh trnh Bn c pha tr-c

Hnh 3.2 S nguyn l mch iu khin bn c

30

3.2 S nguyn l mch ng lc

220AC

Bin p

220/36v

2 D1 4 R4.16 F1 7

R2.1 41R3.1

Rp/di?nR5.1

R5.110R3.140R2.1D3

R4.1

R5.2

PhanhD2

R4.29

R2.2 43 R3.2

R2.2 42 R3.2R4.2

GFED H I J K MA B C

6

5

4

3

2

1

3

Hnh 3.3 S nguyn l mch ng lc cp ngun cho ng c mt chiu lai bn c.

5

31

3.3 Thuyt minh hot ng

3.3.1 Thuyt minh hot ng phn c kh

1. Cu to phn bn c

1) Mt chn bn c

2) ai c

3) Trc vt me

4) ng c mt chiu

5) Encorder phn hi kch thc v chiu quay

6) Dy cualoa lai t puli ca ng c sang puli ca trc vt me

7) Phanh

2. Thuyt minh hot ng

- Sau mi hnh trnh ca dao ct, sau khi dao ct ng v tr , p

nhc ln, lc ny cng tc hnh trnh c tc ng a tn hiu xung v cho b

phn iu khin trung Tm. B phn iu khin trung tm cp lnh cho cc

rle trung gian hot ng phanh c m ra, ng c mt chiu c cp

in ko trc vt me quay thng qua h thng puli v dy cualoa. Trc vt me

v ai c bin chuyn ng quay thnh chuyn ng tnh tin lm mt chn

bn c di chuyn tip hoc li trn mt bn sau ca my ct. Lc ny chuyn

ng l chuyn ng nhanh.. Khi mt bn chn bn c di chuyn gn n

kch thc quy nh phanh c ng li v m ra sau mt khong thi gian

rt ngn hm tc di chuyn ca mt chn bn c sau mt bn c

chuyn ng chm (r) n kch thc quy nh th dng li ci bo hiu s

pht tn hiu cho ngi vn hnh bit. Kch thc t khi mt bn c chuyn

t tc chm dn kch thc quy nh c lp trnh trong b iu khin

trung Tm, kch thc ny c th thay i c t 0 30 MM.

: in p ca ng c 1 chiu l in p cao

: in p ca ng c 1 chiu l in p thp.

32

3.3.2 Thuyt minh hot ng phn in ng lc v iu khin ca ng c lai

bn c.

- Khi cng tc CT1 c bt , b phn iu khin trung tm c in, iu

khin r le R1 ng cp ngun ng c lm vic, ng R5 cp in cho

phanh gi cho bn c c nh khng b di chuyn do tc ng ca ngoi lc.

- Khi c xung tc ng t cng tc hnh trnh c b phn iu khin trung

Tm c tc ng ( gi s ny l hnh trnh tin ca bn c, m t li quay

thun). B phn iu khin trung Tm ng R3, ng R4 m R5 phanh c

m ra sn sng, cho vt me quay M

Mch in 2 D1 4 6 F1 7 41 12 M 11 10 43

9 3

ng c c cp in in p cao v quay theo chiu thun ko mt chn

bn c tin nhanh n gn kch thc quy nh ( khong cch ny c lp

trnh trong b phn iu khin trung Tm). Khi R4 m, R5 ng li ng c

mt ngun, phanh ng li hn vt me. ng c c hm ng nng, nng

lng c gii phng qua in tr phng in.

Rp/ in do tip im R5.1 khp kn mch 11 13 Rp 12.

- Sau thi gian rt ngn b phn iu khin trung Tm R5 ng c c cp

in in p thp 36VDC vt me vn quay thun v mt chn bn c di

chuyn chm (r) n kch thc quy nh.

Mch in 5 6 F1 7 41 12 M 11 10 43 9 8.

Mt chn bn c di chuyn chm n ng kch thc quy nh trc trong

b phn iu khin trung Tm. Lc ny b phn iu khin trung Tm m R3,

ng R5 ngt ngun cho ng c, ng phanh hn mt chn bn c ng v

tr, nng lng t trong phanh c phng qua D2 khi tip im ca R5.2

ng li.

- V tr ca mt chn bn c v chiu quay ca ng c lai bn c c phn

33

hi v b iu khin trung Tm thng qua Encorder

- Khi mt chn bn c chuyn ng li th tng t khi R2 ng cn R3

m.

34

CHNG 4

S MCH NG LC, IU KHIN CA B PHN

DAO CT GIY DNG PLC

4.1 S nguyn l mch iu khin my ct giy bp c XII

Hnh 4.1 S nguyn l mch iu khin

35

4.2 S nguyn l mch ng lc

Hnh 4.2 S nguyn l mch ng lc

36

4.3 Thuyt minh nguyn l hot ng my ct

Khi ng:

Nhn nt Start

Mch 10 11 5 26 K1 0 (cp in cho cun ht

KT K1)

- ng tip im duy tr K1 (1) (Dng B11)

- ng cc tip im mch ng lc

Bung nt Start

Mch 10 11 5 26 K1 0 (Lc ny im 5 lun c

in)

Ct:

a tp giy ct vo my ct

Bm c 5- 30 ng li (Dng E11)

Mch 10 11 5 30 32 27 47 1

Van

du

xung 0

6

28 29

R9

R1

K2

- Van du iu kin ng

- Cun ht R9 c in ng tip im R9 (2) Ni 5 6 (Dng D20)

- Cp in cho cun ht R1 ng tip im 5 36 (Dng

E2)

5 37 (Dng E4)

Gi nguyn c: 5 30

vn ng

37

Mch 10 11 5 36 0TM1

37 (Ch sn)

Trng thi (1) -c gi nguyn

K2 6 0

Cp in cho TM1 sn sng cho tip im thi gian thng m

ng chm (ng G7) nh thi gian tr t khi p i xung n khi ng ly

hp ct.

Sau thi gian tr ca tip im TM1 (dng G7) ng li (lc

ny p p ti mt tp giy trong my)

Mch 10 11 5 7 9 (ch sn)

0TM2

K3 42 40 41 0

K4

- Cp in cho KT: K3, K4 ng in cho ly hp dao ct

- Ly hp ng trc khuu ko dao i xung, ng thi cam

hnh trnh quay. R-le hnh trnh chuyn t v tr 7

9

8

sang v tr

9

8

7

cp in cho R le R4 ng cc tip im:

R4(3) (dng I 3)

R4(1) (dng A11)

R4(2) (dng L6)

R4(4) (dng I5)

38

Mch 10 11 5 37 0TM2

42 40 41

R4

K3

K4

Trong lc ny, nu bung tay c ra 5 30

m R le R1 mt

in nh tip im R1(4) (dng E2) v R1(3) (dng E4) TM1 mt in.

Ko theo tip im TM1 mt in (dng G7) m ra KT: K3,

K4 mt in ly hp dao ct nh ra, dao ct dng gia hnh trnh. Van du

xung mt in p dng (nhng ng c thy lc vn quay do K2 vn c

in).

Sau khi r le R4 c in c th nh tay c 5 30

m ly hp

dao ct vn ng, dao c th i ht hnh trnh.

Trong hnh trnh ca dao ct, khi trc khuu qut qua r le o

chiu hnh trnh p 6

1110

4 cp tip im thng m 4 6 ng li cp

in cho R2 ng tip im duy tr R2(4) (dng I20) t duy tr cho R2 khi cp

tip im 4 6 m ra.

M cp tip im thng ng 10 11 nhng T10 vn ni vi

5 do tip im R4 (1) (dng A11)

Mch 10 11 5 37 0TM2

42 40 41

6 2

K3

K4Van

du

ln

p i ln

39

Dao ct hnh trnh ln ng thi cam hnh trnh dao ct qua

r le hnh trnh t vo cam hnh trnh t chuyn t v tr 9

8

7

sang v tr

7

9

8

cp in cho R5, R6 v lc ny tip im R4(3) (dng L6) ang

ng. R le R5 c in m tip im thng m R5(1) (dng J9) K3, K4 mt

in nh ly hp dao ct dng ng v tr, ng thi nh tip im thng m

R5(3) (dng G5), R4 cha mt in v khi nh tay c 5 30

th R9, R1

mt in nh tip im R1(3) (dng E4) nhng R2(2) dng E3) vn ng.

Khi p chm vo cng tc hnh trnh (dng D18) lm v tr 5 6 tch

ri hon ton tip im R9 (2) (dng D20) m khi R9 mt in r le R2

mt in:

- Nh tip im duy tr R2 (4) (dng I20)

- Nh tip im R2(3) (dng E3) van du ln mt in

- Nh tip im R2(1) (dng H15)

R2(2) (dng E3) m ra lm R4 mt in. Lc ny K2 mt in bm thy

lc ngng bm, van du ln mt in p dng li v tr ct.

Dao dng ng v tr, dng v tr cao kt thc mt hnh trnh ct.

Cc trng hp thay dao ct.

n nt IN CHING 5-44 (t hm) r le R7 c in nh tip im R7

(dng F12) ng R7(1) (dng G11) nh R7(2) (dng E5) ng R7(3) (dng

A12). Bp tay c 5 30

Mch 10 11 5 37 0

42 40 41 K3

K4

Lc ny ch c dao xung, p khng xung

n nt Stop KT: K1 mt in ng c ch cn quay theo qun tnh,

tip im K1(1) (dng B11) m ra, tip im thng m K1(3) ng li

40

(dng A10). n nt CLUTCH (dng K9) ng li

0K3

K4

Mch 10 39 40 41

Ly hp dao ct i xung nh qun tnh ca ng c.

4.4 Gii thiu v thit b iu khin logic kh trnh S7-200

4.4.1 Cu hnh cng

PLC, vit tt ca Programmable Logic Control ,l thit b iu

khin loogic lp trnh c, hay kh nng trnh ,cho php thc hin linh hot

cc thut ton iu khin logic thng qua mt ngn ng lp trnh.

S7-200 l thit b iu khin logic kh trnh loi nh ca hng

Siemns (CHLB C), c cu trc theo kiu modul v c cc modul m rng.

Cc modul ny c s dng cho nhiu nhng ng dng lp trnh khc nhau.

Thnh phn c bn ca S7-200 l khi vi s l CPU hoc CPU214 .V hnh

thc bn ngoi ,s khc nhau ca hai hnh thc CPU ny nhn bit c nh

s u vo/ra cc ngun cung cp.

- CPU 212 c 8 cng vo v 6 cng ra c kh nng c m

rng thm bng 7 modul m rng.

- CPU 214 c 14 cng vo v 10 cng ra v c kh nng

c m rng thm bng 7 modul m rng

S7-200 c nhiu modul m rng khc nhau .

CPU 212 bao gm :

- 512 t n (word ), tc l 1K byte , lu chng trnh thuc min b

nh oc/ghi c m khng b mt d liu nh c giao din vi EEPROM.

Vng nh vi tnh cht nh vy c gi l vng nh non-volatile.

- 512 t n lu d liu ,trong c 100 t nh c/ghi thuc min

41

non-volatile.

- c 8 cng vo logic v 6 cng ra logic

- C th ghp ni thm 2 modul m rng mt s cng vo /ra, bao

gm c modul tng t (analog).

- tng s cng logic vo /ra cc i l 64 cng vo v 64 cng ra .

- 64 b to thi gian tr (time), trong c 2 timer c phn gii 1ms,

8 timer c phn gii 10 ms v 54 timer c phn gii 100 ms.

- 64 b m (coumter), chia lm hai loi :loi b m ch m tin v

loi b m ch m li .

- 368 bit nh c bit, s dng lm cc bt trng thi hoc cc bit t ch

lm vic .

- C ch ngt v x l tn hiu ngt khc nhau bao gm :ngt truyn

thng, ngt theo sn ln hoc sn xung ,ngt theo thi gian v ngt bo

hiu ca b m tc cao (2KHz).

- B nh khng b mt gi liu trong khong thi gian 50 gi khi PLC b

mt ngun nui .

CPU 214 bao gm :

- 2048 t n (4K byte) thuc min nh oc/ghi non-

volatile lu chng trnh (vng nh c giao din vi EEPROM )

- 2048 t n (4K byte) kiu c/ ghi lu d liu ,trong

c 512 t u thuc min non-volatile.

- 14 cng vo v 10 cng ra logic

- C 7 modul m thm cng vo /ra bao gm c modul

anlong.

- Tng s cng vo/ra cc i l 64 cng vo v 64 cng ra.

- 128 timer chia lm 3 loi theo phn gii khc nhau :4

timer 1ms, 16 timer 10ms, v 108 timer 100ms.

- 128 b m chia lm hai loi :ch m tin v va m

42

tin va m li

- 688 bit nh c bit dng thng bo trng thi v t

ch lm vic

- Cc ch ngt v s l ngt bao gm :ngt truyn thng

,ngt theo sn ln hoc sn xung ,ngt thi gian ,ngt ca b m tc

cao v ngt truyn xung

- 3 b m tc cao vi nhp 2KHz .

- 2 b pht xung nhanh cho dy kiu PTO hoc kiu PWM.

- 2 b iu chnh tng t.

Ton b vng nh khng b mt d liu trong khon thi gian

190 gi khi LPC b mt ngun nui .

M t cc n bo trn S7-200,CPU214:

SF

(n )

n SP bo hiu h thng b hng .n SF sng ln khi PLC c

hng hc

RUN

(n vng )

n xanh RUN ch nh PLC ang ch dng.Dng chng trnh

ang thc hin li

Lx.x

(n xanh)

n vng cng vo ch nh trng thi tc thi ca cng

Lx.x (x.x=0.0-1,5) n ny bo hiu trng thi ca tn hiu theo gi

tr logic ca cng.

Qy.y

(n xanh )

n xanh cng ra bo hiu trng thi tc thi ca cng

Qy.y (y.y=0,0-1,1) n ny bo hiu trng thi ca tn hiu theo gi

tr logic ca cng .

Cng truyn thng:

S7-200 s dng cng truyn thng ni tip RS485 vi phch ni thit b

lp trnh hoc cc trm PLC khc .Tc truyn cho my lp trnh kiu PPl l

9600 band.Tc truyn cung cp ca PLC theo kiu t do l t 300 n

43

38.400.

Hnh 4.3 S chn ca cng truyn thng

ghp ni S7-200 vi my lp trnh PG702 hoc vi cc loi my lp

trnh thuc h PG7xx c th s dng mt cp ni thng qua MPL. Cp i

km theo my lp trnh .

Ghp ni S7-200 vi my tnh PC qua cng RS-232 cn c cp ni

PC/PPl vi b chuyn i RS232/RS485.

Cng tc chn ch lm vic cho PLC.

Cng tc chn ch lm vic nm pha trn, bn cnh cc cng ra ca

S7-200 c ba v tr cho php chn cc ch lm vic khc nhau cho PLC.

- RUN cho php PLC thc hin chng trnh trong b nh .PLC S7-200

s ri kh ch RUN v chuyn sang ch STOP nu trong my c s c,

hoc trong chng trnh gp lnh STOP, thm ch ngy c khi cng tc ch

RUN.Nu quan st trng thi thc ti ca PLC theo n bo.

- STOP cng bc PLC cho php hiu chnh li chng trnh hoc lp

mi chng trnh mi .

- TERM cho php my lp trnh t quyt nh mt trong ch lm vic

cho PLC hoc RUN hoc STOP.

Ch nh tng t

5 4 3 2 1 3

6 9 8 7

Chn Gii thch

1. t

2. 24 VDC

3. Truyn v nhn gi liu

4. Khng s dng

5. t

6. 5 VDC (in tr trong 100 )

7. 24VDC (120mA ti a)

8. Truyn v nhn gi liu

9. Khng s dng

44

iu chnh tng t (1b trong CPU 212 v b trong CPU 214) cho

php iu hnh cc bin cn phi thay i v s dng trong chng trnh.

Nm chnh analog c lp t di np y bn cnh cc cng ra. Thit b

chnh nh c th quay 270 .

Pin v ngun nui b nh

Ngun nui dng ghi chng trnh hoc lp mt chng trnh mi

.

Ngun pin c th c s dng m rng thi gian lu gi cho cc d

liu trong b nh. Ngun pin t ng c chuyn sang trng thi tch cc

nu nh dung lng t nh b cn kit v n phi thay th vo v tr d

liu trong b nh khng b mt i.

4.4.2 M rng cng vo ra

CPU212 cho php m rng nhiu nht 2 modul v CPU214 nhiu nht 7

modul. Cc modul m rng tng t v s u c trong S7 200

C th m rng cng vo/ ra ca PLC bng cch ghp ni thm vo n

cc modul m rng v pha bn phi ca CPU, lm thnh mt mc xch. a

ch ca cc v tr ca modul c xc nh bng kiu vo/ra v v tr ca

modul trong mc xch, bao gm cc modul c cng kiu. V d nh mt

modul cng ra khng th gn a ch ca mt modul cng vo cng nh mt

modul tng t khng th c a ch nh mt modul s v ngc li.

Cc modul m rng s hay ri rc u chim ch trong b m, tng t

vi s u vo/ra ca modul.

Sau y l mt v d v cch t a ch cho cc modul m rng trn

CPU214:

CPU214 Modul 0

(4 vo/ 4ra)

Modul 1

8 vo

Modul 2

3 vo

analog/ 1 ra

analog

Modul 3

8 ra

Modul 4

3 vo

analog/ 1 ra

analog

45

10.0 Q0.0 12.0 13.0 0 Q3.0 AIW8

10.1 Q0.1 12.1 13.1 0 Q3.1 AIW10

10.2 Q0.2 12.2 13.2 0 Q3.2 AIW12

10.3 Q0.3 12.3 Q3.3

10.4 Q0.4 Q3.4 AQW4

10.5 Q0.5 Q2.0 Q3.5

10.6 Q0.6 Q2.1 Q3.6

10.7 Q0.7 Q2.2 Q3.7

11.0 Q1.0 Q2.3

11.1 Q1.1

11.2

11.3

11.4

11.5

4.4.3 Thc hin chng trnh

PLC thc hin chng trnh theo chu trnh lp. Mi vng c gi l

vng quyt (scan) .Mi vng qut c bt u bng giai on c gi liu t

cc cng vo vng b m o ,tip theo l giai on thc hin chng

trnh.Trong tng vng qut, chng trnh c thc hin bng lnh u tin

v kt thc ti lnh kt thc (MEND), sau khi giai on thc hin chng

trnh l giai on truyn thng ni b v kim li.Vng qut c kt thc

bng giai on chuyn cc ni dung ca b m o ti cc cng ra.

Nh vy, ti thi im thc hin lnh vo/ra ngay, thng thng lnh

khng lm vic trc tip vi cng vo ra m ch thng qua b m o ca

cng trong vng nh tham s. Vic truyn thng gia b m o vi ngoi vi

trong cc giai on 1 v 4 do CPU qun l. Khi gp lnh vo ra ngay lp tc

th h thng s cho dng mi vic khc, ngay c chng trnh x l ngt,

46

thc hin lnh ny mt cch trc tip vi cng vo/ ra.

Nu x dng cc ch ngt, chng trnh con tng ng vi tng tn

hiu ngt c son tho v ci t nh b phn ca chng trnh. Chng

trnh s l ngt ch c thc hin trong vng qut khi xut hin tn hiu bo

ngt v c th xy ra bt k thi im no trong vng qut.

4.4.4 Cu trc chng trnh ca S7 200

C th lp trnh cho PLC S7 200 bng cch s dng mt trong nhng

phn mm sau y:

Step 7 Micro/DOS

Step 7 Micro/WIN

Nhng phn mm ny c th u c th ci t c trn cc my lp

trnh h PG7xx v cc my tnh cc nhn (PC).

Cc chng trnh cho S7 200 phi c cu trc bao gm chng trnh

chnh (main program) v sau n cc chng trnh con v cc chng

trnh s l ngt c ch ra sau y:

Chng trnh chnh c kt thc bng lnh kt thc chng trnh

(MEND)

- Cc chng trnh con c nhm li thnh mt nhm ngay sau chng

trnh chnh.Sau n ngay cc chng trnh x l ngt.Bng cch vit nh

vy, cu trc chng trnh c r rng v thun tin hn trong chng vic

c chng trnh sau ny. C th t do trn ln cc chng trnh con v

chng trnh x l ngt ng sau chng trnh chnh.

2.Ngn ng lp trnh ca S7-200

4.4.5 Phng php lp trnh

S7-200 biu din mt mch logic cng bng mt dy cc lnh lp trnh

u tin v kt thc lp trnh cui trong mt vng. Mt vng nh vy c

gi l vng qut (scan)

47

Mt vng qut (scan clycle) c bt u bng vic c trng thi ca

u vo,v sau thc hin chng trnh. Scan clycle kt thc bng vic thay

i trng thi u ra.Trc khi bt u mt vng qut tip theo S7-200 thc

thi cc nhim v truyn thng .Chu trnh thc hin chng trnh l chu trnh

lp(xem hnh 2.1)

Cch lp trnh cho S7-200 ni ring v cho cc PLC ca Siemens ni

chung da trn hai phng php c bn: phng php hnh thang (ladder

logic vit tt thnh LAD) v phng php lit k lch (statement Lt vit tt

thnh STL). Chng ny s gii thiu cc thnh phn c bn ca hai phng

php trn v cch s dng chng trong lp trnh.

Nu chng trnh c vit theo kiu LAD, thit b lp trnh s t to ra

mt chng trnh theo kiu STL tng ng. Ngc li khng phi mi

chng trnh c vit theo kiu SLT cng c th chuyn sang dng LAD.B

lnh ca phng php SLT c trnh by trong quyn sch ny u c mt

chc nng tng ng nh cc tip im, cc cun dy v cc hp dng trong

LAD.Nhng lnh ny phi c v phi hp c trng thi ca cc tip im

a ra c mt quyt nh v gi tr trng thi u ra hoc mt gi tr

logic

Cho php, hoc khng cho php thc hin chc nng ca mt (hay

nhiu) hp. d dng lm quen vi cc thnh phn c bn ca LAD v ca

STL cn phi nm c cc inh ngha c bn sau y:

nh ngha v LAD: LAD l mt ngn ng lp trnh bng ha.

Nhng thnh phn c bn dng trong LAD tng ng vi cc thnh phn ca

bng iu khin bng rle. Trong chng trnh LAD cc phn t c bn dung

biu din lnh logic nh sau:

-Tip im: l biu tng (symbol) m t cc tip im ca rle. Cc

tip im c th l thng m -| |- hoc thng ng -| /|-

- Cun dy (coil) l biu tng -( )- m t r le c mc theo chiu

48

dng in cung cp cho rle.

- Hp (box): l biu tng m t cc hm khc nhau n lm vic khi c

dng in chy n hp. Nhng dng hm thng c biu din bng hp l

cc b thi, gian (Timer), b m (coumter) v cc hm ton hc. Cun dy

v cc hp phi c mc ng chiu dng in.

- Mng LAD: l ng ni cc phn t thnh mt mch hon thin, i t

ng ngun bn tri sang ng ngun bn phi. ng ngun bn tri l

dy nng, ng ngun bn phi l dy trung ha (neutral) hay l ng tr

v ngun cp (ng ngun bn phi thng khng th thc hin khi dng

chng trnh tin dng STEP 7 micro/DOS hoc STEP 7 micro/WIN).

Dng in chy t tri qua cc tip im ng n cc cun dy hoc cc hp

tr v bn phi ngun.

nh ngha v STL:

Phng php lit k lnh (STL) l phng php th hin chng trnh

di dng tp hp cc cu lnh. Mi cu lnh trong chng trnh, k c

nhng lnh hnh thc biu din mt chc nng ca PLC

nh ngha v ngn xp logic (loic stack)

S0 Stack 0 bit u tin hay bit trn cng ca ngn xp

S1 Stack 1 bit th hai ca ngn xp

S2 Stack 2 bit th ba ca ngn xp

S3 Stack 3 bit th t ca ngn xp

S4 Stack 4 bit th nm ca ngn xp

S5 Stack 5 bit th su ca ngn xp

S6 Stack 6 bit th by ca ngn xp

S7 Stack 7 bit th tm ca ngn xp

S8 Stack 8 bit th chin ca ngn xp

to ra mt chng trnh dng STL, ngi lp trnh cn phi hiu r

49

phng thc s dng 9 bit ngn xp logic ca S7 200. Ngn xp logic l

mt khi gm 9 bti chng ln nhau. Tt c cc thut ton lin quan n ngn

xp u ch lm vic vi bit u tin hoc vi bit u v bit th hai ca ngn

xp. Gi tr logic mi u c th c gi (hoc c ni thm) vo ngn

xp. Khi phi hp hai bit u tin ca ngn xp, th ngn xp s c ko ln

mt bit. Ngn xp v tn ca tng bit trong ngn xp c biu din trong

hnh 4.4

LAD STL

10.0 Q1.0 LD 10.0

|| | ( ) = Q1.0

Hnh 4.4 M t lnh LAD v STL

4.5 Chuyn mch iu khin Relay Contactor sang iu khin PLC S7-

200

4.5.1 Thut iu khin

50

Start

Bm c

Dao ct i xung p i xung

p i ln

p dng

Dao ct i ln

Dao ct dng

Tr 0,5s

Chm cng tc

o chiu

Chm cng tc gii hn

hnh trnh

Cam hnh trnh chm

cng tc hnh trnh

C ng kch thc

51

4.5.2 Cc u vo, ra v s d nguyn l mch ngoi PLC

1. u vo

1) I0.0 Start

2) I0.1 Stop

3) I0.2 C (Thng m)

4) I0.3 Cam

5) I0.4 Cng tc khng ch ln

6) I0.5 Cng tc o chiu

7) I0.6 xung

8) I0.7 ln

9) I1.0 Tip im kch thc chun

10) I1.1 Tip im thc ng INCHING

11) I1.2 Tip im thc m INCHING

12) I1.3 C (thng ng)

2. u ra

1) Q0.0 ng c dao

2) Q0.1 ng c thy lc

3) Q0.2 Van du xung

4) Q0.3 Van du ln

5) Q0.4 Ly hp

52

53

4.5.3 Chng trnh iu khin PLC S7- 200 bng ngn ng LAD

54

55

56

57

KT QU THC NGHIM TRN M HNH

1. Gii thiu cc phn t trn m hnh

* Cng tc ngun

* Cu ch

* Cc nt iu khin: START, STOP, UP, DOWN, CLUTCH,

INCHING tng ng vi cc nt iu khin thit b thc t.

* Cc cng tc hnh trnh:C, CAM, /C , G/H TRN tng

ng vi cc cng tc hnh trnh trn thc t.

* Cng tc: KCH THC CHUN tng ng vi tip im c

iu khin bi computer khi bn c ng kch thc chun.

* Cc Rle u ra (ng thi l r le hin th): /cDAO, THU

LC, XUNG, LN, LY HP.

* it cu, t lc.

* Dn cu u cc u vo ra.

2. M t thc nghim trn m hnh

- Bt cng tc ngun cp in cho m hnh: n hin th ngun sng

- Nhn nt START: Rle /c Dao sng (ng c dao c cp in)

+ Nhn cng tc c: Cc R le THU LC, XUNG, LY HP

sng (ng c thu lc quang, van du xung m, ly hp ng sau 0.5s)

+ Gi nguyn cng tc c, nhn nh cng tc /ch , nhn v gi

CAM, sau khi cng tc CAM nh cng tc c: cc rle THU LC,

LN, LY HP sng (ng c thu lc quay, van du ln m, ly hp vn

ng).

+ Nh cng tc CAM: R le LY HP tt (LY HP nh)

+ Nhn nh cng tc G/H TRN : Rle THU LC, LN tt

(ng c thu lc ngng quay, van du ln ng)

Ht mt chu trnh ct.

58

- Nhn nt INCHING

+ Nhn cng tc c: R le LY HP sng, nh cng tc c Rle LY

HP tt (ch c dao ct lm vic, dng thay i dao)

- Nhn nt CLUTCH: ch c role LY HP sng c role /C DAO

cng tt (dng thay dao nh qun tnh ca ng c dao)

- Nhn nt STOP: Cc role tt (dng lm vic)

59

KT LUN

ti Nghin cu tm hiu h thng my ct giy trong nh my giy

trong nh my giy HAPACO. i su ci tin quy trnh ct giy bng PLC

ca em gii quyt mt s vn sau:

- Nghin cu tng quan v cng nghip sn xut giy, cng ngh sn

sut giy t b ma.

- i su nghin cu v my ct giy XII bao gn: nghin cu tng quan

v my ct giy, nghin cu cu to, chc nng nhng b phn chnh ca

my, t thit b v quy trnh vn hnh thc t v li s nguyn l mch

iu khin, mch ng lc ca b phn bn c, b phn dao ct, thuyt minh

quy trnh hot ng ca hai b ny (do thit b lu ngy, h s k thut b

tht lc, mt mt).

Do thit b s dng iu khin b phn sao ct s dng bng Relay-

contactor, tin cy cao hn (iu ny rt cn thit khi sn xut theo dy

chuyn). V y l vn thc t nn em cha c iu khin PLC vo thit

b thc m mi ch chy trn m hnh.

Em xin c s ch bo, gp ca thy c ti ca me c hon

thin hn. Cui cng em xin trn trng cm n thy Hiu trng, Ban Gim

hiu nh trng, cc phng ban chc nng, thy trng khoa in, cc thy

c trong khoa in v c bit l thy Nguyn on Phong l ngi trc tip

hng dn em thc hin ti.

Hi Phng, ngy ....thng.....nm 2010.

Sinh vin thc hin

Phm Trung Dng

60

61

TI LIU THAM KHO

1. GS TSKH Thn Ngc Hon, TS Nguyn Tin Ban - iu chnh t ng

cc h thng truyn ng NXB khoa hc k thut 2007.

2. L Thnh Bc - Gio trnh thit b in NXB khoa hc k thut 2001.

3. Nguyn Don Ph-c, Phan Xun Minh T ng ho SIMATIC S7200

- Nh xut bn nng nghip 1997.

4. V Minh Chnh (ch bin), Phm Quc Hi, Trn Trng Minh - in t

cng sut NXB Khoa hc v K thut 2007.

5. Nguyn Mnh Tin, V Quang Hi Trang b in in t my gia cng

kim loi NXB gio dc 2001.

6. V Quang Hi Trang b in in t cng nghip NXB gio dc -

2002

7. PGS TSKH Thn Ngc Hon My in NXB giao thng vn ti

1999

8. Bi Vn Yn - Sa cha in my cng nghip NXB Hi Phng - 1998

62

MC LC

CHNG 1 TNG QUAN V CNG NGH SN XUT GIY ............. 2

1.1 Gii thiu tng quan v cng ty cp hapaco ..................................................... 2

1.2 Quy trnh cng ngh chung sn xut giy .................................................. 5

1.3 Quy trnh cng ngh sn xut giy t b ma ................................................. 9

1.4 Mt s ch tiu kinh t ................................................................................... 15

CHNG 2 TNG QUAN V DY TRUYN V KT CU C KH

CA MY CT GIY XII .............................................................................. 19

2.1 Gii thiu chung v cu to chc nng s dng ca my ct giy bp c

XII ....................................................................................................................... 19

2.2 Cc bn v c kh minh ha chc nng ca cc chi tit my ....................... 20

CHNG 3 S NGUYN L MCH IU KHIN, MCH

NG LC, NGUYN L HOT NG B PHN BN C ............... 27

3.1 S nguyn l mch iu khin ................................................................. 27

3.2 S nguyn l mch ng lc .................................................................... 30

3.3 Thuyt minh hot ng ................................................................................. 31

3.3.1 Thuyt minh hot ng phn c kh ..................................................................... 31

3.3.2 Thuyt minh hot ng phn in ng lc v iu khin ca ng c lai bn

c. .................................................................................................................................. 32

CHNG 4 S MCH NG LC, IU KHIN CA B

PHN DAO CT GIY DNG PLC ............................................................. 34

4.1 S nguyn l mch iu khin my ct giy bp c XII ......................... 34

4.2 S nguyn l mch ng lc .................................................................... 35

4.3 Thuyt minh nguyn l hot ng my ct ................................................... 36

4.4 Gii thiu v thit b iu khin logic kh trnh S7-200 ............................... 40

4.4.1 Cu hnh cng ...................................................................................................... 40

4.4.2 M rng cng vo ra ............................................................................................ 44

4.4.3 Thc hin chng trnh ........................................................................................ 45

63

4.4.4 Cu trc chng trnh ca S7 200 .................................................................... 46

4.4.5 Phng php lp trnh ......................................................................................... 46

4.5 Chuyn mch iu khin Relay Contactor sang iu khin PLC S7-200 . 49

4.5.1 Thut iu khin .................................................................................................. 49

4.5.2 Cc u vo, ra v s d nguyn l mch ngoi PLC ......................................... 51

4.5.3 Chng trnh iu khin PLC S7- 200 bng ngn ng LAD .............................. 53

KT QU THC NGHIM TRN M HNH ............................................ 57

1. Gii thiu cc phn t trn m hnh ........................................................... 57

2. M t thc nghim trn m hnh ................................................................. 57

TI LIU THAM KHO ................................................................................ 61