Beer filling, Gland machine PLC control system rduction
Malt beer production process is divided into manufacturing, manufacturing wort, before fermentation, after fermentation, filtration sterilization, packaging, and so few procedures. Beer filling, Gland part of a packaging machine processes. The membrane filtration of beer after the pipeline into the rotary Jiugang, then the valve into the bottle of wine, Gland, was bottled beer. Beer filling, Gland machine's efficiency and degree of automation direct impact on the level of beer production.
China's beer industry to meet the increasing scale of production and the demand for beer modern high-speed filling machinery filling the requirements of domestic beer manufacturers are actively seeking to transform the unit or the filling of beer production equipment, making it a good use Performance, advanced technology and high production efficiency and operating a safe and secure, low maintenance costs of the modernization of beer filling machine. 2. Filling beer, Gland principle and control aircraft parts
Liquid filling machine by filling principle can be divided into atmospheric filler,filling machines and vacuum pressure on the filling machine. Beer filling,Gland-filling method used pressure is higher than the atmospheric pressure under the filling, storage of the cylinder pressure than the pressure of the bottle, beer bottle into the liquid on pressure.
Technology at home and abroad to achieve the filling line is basically: The Rotary Jiugang the rotating movement, placed in Jiugang slots on the empty bottles through the machinery will be fixed at the upper Jiugang vacuum valve to open, closed Vacuum bottles for good treatment, Bozhuan stem from operating, open the valve of the bottle filling CO2 gases, vacuum convex d to open the vacuum valve, the bottle will air mixed with CO2 out of gas, open the valve again, the CO2 gas bottle filling, the filling valve on the pressure valve in the bottle close to back-pressure gas pressure at the open-Jiuye Pingbi into the bottle, through pneumatic or electrical control filling valve to achieve the filling of beer.
Today's advanced international beer filling, Gland machine control system mainly by the photoelectric switch position detection part and take the bottles with, Jiugang speed part, dominated by the PLC, touch screen and other components. Filling, Gland of the mechanical structure and PLC programmable control devices, frequency stepless speed regulation, human-computer interface, and other modern means of complete automatic control technology, the combination of a mechanical and electrical integration.
3. Controlled part of the programme
Many domestic beer manufacturers are now using the filling, Gland of the control system of uneven degree of automation; button and all the manual switch technology have set up operations in a box on the panel, PLC controller for the majority of Japanese companies or OMRON Mitsubishi's early products, equipment chain of control, less protection settings, plus the beer filling the scene poor environment, humidity, such as contact with the switch contacts serious corrosion, the system's signal detection of the high failure rate, resulting in equipment control system Operation of low reliability, the normal operation of equipment, such as short-cycle phenomenon.
To the actual transformation of the Dandong Yalu River Brewery Co., Ltd. of filling, Gland machine control system as an example, the transformation of methods to clarify the control of such equipment thinking and ideas, according to the scene of the actual process conditions, to prepare the operation of the PLC Procedures. For beer filling, Gland control system of the actual situation and in accordance with the actual process conditions at the scene, re-design of the equipment of the PLC control system. This transformation of the same methods and ideas can be applied to other liquids and the transformation of filling equipment. 3.1 system hardware configuration
Japan's Mitsubishi Corporation to use the FX2N128MRPLC use the system to replace the original 2-OMRON's C60P PLC, the original system of the PLC is due to old models, and computer on-line communications need to configure special converters, the system need to increase the external I / O input points , The extension of spare parts more difficult to find. FX2N128MRPLC is an integrated 128-point I / O controller of the box, a computing speed, command rich, high-cost performance, on-line programming simple and easy extension of the advantages of the Mitsubishi FX series, features the strongest small controller .
(1) by the Mitsubishi 900 series of 970 GOT human-computer touch screen system to replace the original use of the button panel display equipment and monitor the operation of operating parameters. 970GOT HMI for the 16-color high-brightness significantly, through the convergence of connectivity and FX2N128MRPLC directly connected to the CPU, achieving rapid response. Has many maintenance features, such as the list-editing features, ladder monitoring (troubleshooting) function, the system monitoring functions to find fault and maintenance of PLC Systems.
(2) filling, Gland of the frequency converter in the transformation of no replacement, on-site detection signal means-testing is still used switch, switch for detecting long-term work in the humidity of the great occasions, the choice of capacitive proximity switches, according to PLC I / O terminal of the connection mode, select the type of close PNP switch, the control system of Figure 1. 3.2 Systems Programming
PLC controller programming focus and the core is around Jiugang the rotation speed control and Jiugang on 60 bottles of detecting the location of the displaced, broken bottles, empty bottles at the location of testing and related displacement filling Such as control valves. The bottles displacement of testing procedures, using a Mitsubishi PLC in the left re 1 control system structure diagram .
Bottles displacement of detection, using the left-PLC command, which commands the whole of one of the core control procedures, the main electrical switch detection and bottles at the bottle simultaneously detect mobile, the main motor to every week, just to the corresponding Jiugang Have a bottle of, PLC unit within the internal correspondence that 60 bottles of the unit for the M500 ~ M559, the number of units by the first letter K is set to K60, with each change in a second letter K is set to K1, M50 Reaction of the empty bottles in the short position, and detect the location of the motor speed to go on the frequency shift in the corresponding unit within the built-in "1" or "0", control valves and the corresponding mixing caps The motor stopped and opened. Continuous detection system in place after the 90 empty bottles, stop stirring caps the motor running, testing the number of bottles in accordance with the user's requirements can be arbitrary.
A bottle of detection. Rotary Jiugang through pressure to back pressure with the bottle of liquor in the process of empty bottles in the back-pressure, because the bottle itself may crack and other reasons leading to a sudden burst bottles, which need to detect the location of unexploded bottle bottle, in this bottle - The position opened purge solenoid valves, compressed air out, broken bottles at the bottle-blowing from the position in a row after the purge and several bottles of the electromagnetic valve open jet, a high-pressure spray Shuizhu, in the break Bottle position around a few bottles of spray bottles in a row.
Detection of broken bottles and bottle-detection switch simultaneously detect movement of breaking bottles, to the main motor of each week, precisely corresponding Jiugang passed a bottle of, PLC unit within the internal correspondence that 20 broken bottles at the unit for the M600 ~ M619, unit With the number of the first letter K is set to K20, with each change in a second letter K is set to K1, M52 response to the location of the broken bottles and detected the location of the motor speed to the frequency shift continue, In the corresponding unit within the built-in "1" or "0", control and the corresponding jet purge solenoid valve opened and stopped. Continuous Spray and purge solenoid valve open to listen, time stopped in accordance with technological requirements can be arbitrary.
System security is to control access to the caps simultaneously tracking, not only accurately detect the electrical switching speed detection, the broken bottles into the bottle and detection switch detection switch three conditions.
970GOT human-computer touch-screen terminals operated by the software company's Mitsubishi GT WORKS package, which is a GT Designer with the entire GOT9000 series of graphics software packages. The package is simple, prior to a personal computer simulation on the configuration and debug, after the man-machine operators to download terminals. At the same time, because the man-machine interface and a touch-screen role, will set common switch on the screen to facilitate the operation. And also to increase the number of features, such as setting alarm information. r transformation control system
System at the normal operation of the machine for automatic control, in accordance with bottles into and out of the bottle for lack or slow pace set by running into the bottle stall bottles, no less than a bottle cap, automatic washing bottles burst, filling automatic back-pressure position , Covered under the system automatically lose covered a stop and safety protection, such as the coordination of action interlock. All the original button after the operation of the touch screen on. ction of the state control system monitoring
Detection switch into the bottle and break bottles detection switch bottles of pressure by testing each part of the small metal plates above the location of a photoelectric pulse output, a further PLC acquisition, as each bottle of the pressure above the small metal plates is the location of activities , In the machine running after some time, some pressure above the small bottles of iron tablets and detection switch in the location of displacement, resulting in detection switch mistaken judgement, if not for the judgement of bottles of bottles, bottle explosion Lou Jian, misuse, such as the seizure of output errors So that the PLC have mistaken action, such as a back-pressure, unexploded bottle blowing, washing, stirring cap control system malfunction, such as failure phenomenon.
Before the transformation of the daily production process, encountered this phenomenon, the operatives could only switch to the various functional or manual control buttons reach the stall so that the equipment work in the absence of monitoring state, the machine lost control function. Caused a lot of production of raw materials such as gas, water, wine waste. Only in the production of intermittent, can be fitter and maintenance electrician in accordance with the detection of small switch on the light-emitting diodes and anti-displacement by adjusting the distance only 5 ~ 8 mm detection switch installation location, and switch to fix detection of small metal plates Gap. This means of detection is very backward, after adjustment reaction to the results, timely response can not be adjusted results.
In view of this testing situation, after the transformation of the filling, Gland control system configuration, this part of a new detection and integration in human-computer touch screen, complete bottle of detection.
In human-computer touch screen interface on the page display, respectively, at customs, such as electromagnetic motor mixing valve switch state are in different colors to show, very intuitive.
Increase the system's functions is to ensure the irrigation of the machine-Gland normal operation of automated control system specifically designed to. 6 Concluding remarks
After the transformation of the control system will greatly simplify the complicated mechanical structure, the running and control of inspection, the degree of automation systems meet the design requirements, greatly reducing the operational strength of the labor so that the shrub-like beer output than in the past Raising more than 30 percent, greatly reduce the failure rate. Embodies the modern equipment of automatic control technology. In the digestion and absorption of today's industrial control on the basis of advanced technology innovation, development of domestic technology from the most advanced filling control system.
啤酒灌裝、壓蓋機PLC控制系統
1、引言
啤酒生產過程分爲麥芽製造、麥芽汁製造、前發酵、後發酵、過濾滅菌、包裝等幾道工序。啤酒灌裝、壓蓋機部分屬於包裝工序。啤酒經膜過濾後由管路送入迴轉酒缸，再經酒閥進入瓶子中，壓蓋後獲得瓶裝啤酒。啤酒灌裝、壓蓋機的工作效率和自動化程度的高低直接影響啤酒的日產量。
爲了滿足我國啤酒行業日益擴大生產規模的需求和啤酒現代化灌裝機械高速灌裝的要求，國內各啤酒生產廠家都在積極尋求或改造本單位的啤酒灌裝生產設備，使其成爲具有良好的使用性能，先進的技術水平及高生產效率、運行穩妥可靠、維護成本低的啤酒現代化灌裝機。
2、啤酒灌裝、壓蓋機工作原理和控制部分構成
液體灌裝機按灌裝原理可分爲常壓灌裝機、壓力灌裝機和真空灌裝機。啤酒灌裝、壓蓋機採用壓力灌裝方法，是在高於大氣壓力下進行灌裝，貯液缸內的壓力高於瓶中的壓力，啤酒液體靠壓差流入瓶內。
目前國內外實現灌裝工藝路線基本上是：利用迴轉酒缸產生的旋轉運動，使安放在酒缸槽位上的空瓶通過機械機構將固定在酒缸上部的欲抽真空閥打開，對已封好的瓶子進行抽真空處理，撥轉外操作閥杆，打開氣閥，對瓶內充填CO2氣體，抽真空凸輪繼續打開真空閥，將瓶內空氣與CO2混合氣體抽出，氣閥再次打開，對瓶內充填CO2氣體，灌裝閥內的液閥在瓶內壓力接近背壓氣體壓力時打開，酒液順瓶壁注入瓶內，通過氣動或電動控制灌裝閥實現啤酒的灌裝。
當今國際先進的啤酒灌裝、壓蓋機的控制系統主要由光電開關位置檢測部分、走瓶帶、酒缸轉速的變頻調速部分、主控由可編程控制器、觸摸屏等組成。灌裝、壓蓋機的機械結構裝置與PLC可編程控制、變頻無級調速、人機界面等現代自動控制技術手段完整的結合，形成機電一體化。
3、控制部分改造方案
國內很多啤酒廠家現使用的灌裝、壓蓋機的控制系統的自動化程度參差不齊；所有手動按鈕和工藝開關都設置在一個操作箱的面板上，PLC控制器大都爲日本OMRON公司或三菱公司的早期產品，設備連鎖控制、保護設置少，加之啤酒灌裝的現場環境惡劣，潮溼度大，使開關等接觸觸點鏽蝕嚴重，系統的信號檢測部分故障率較高，造成設備控制系統運行的可靠性低，設備正常運行週期短等現象。
以實際改造的丹東鴨綠江啤酒有限公司的灌裝、壓蓋機的控制系統爲例，介紹改造方法，闡明改造這類設備的控制思想和思路；根據現場的實際工藝條件，重新編寫了PLC的運行程序。針對啤酒灌裝、壓蓋機控制系統的實際狀況，並根據現場的實際工藝條件，重新設計了設備的PLC控制系統。這種改造方法和思路同樣可以應用與其他液體介質灌裝設備的改造。
3.1系統硬件配置
使用日本三菱公司的FX2N128MRPLC替換原系統使用的'2臺OMRON公司的C60P PLC，原系統的PLC由於是老型號產品，和計算機聯機需要配置特殊的通訊轉換器，系統需要增加外部I/O輸入點時，擴展模塊備件較難尋。FX2N128MRPLC是集成128點I/O的箱體式控制器，具有運算速度快，指令豐富、性能價格比高、聯機編程簡單、擴展方便等優點，是三菱FX系列中功能最強的小型控制器。
(1)採用三菱公司的900系列的970GOT人機觸摸屏替換原系統使用的面板按鈕並監控顯示設備的運行工作參數。970GOT HMI爲高亮度的16色顯，通過匯流連接和FX2N128MRPLC的CPU直接連接，實現快速回應。具有許多維護功能，如列表式編輯功能、梯形圖監控(故障查找)功能、系統監控功能等用來查找故障和維護PLC系統。
(2)灌裝、壓蓋機的變頻器在改造中沒有更換，現場檢測信號的手段仍然採用開關式檢測，因檢測開關長期工作在溼度很大的場合，因此選擇電容式的接近開關，根據PLC I/O端子的接線方式，選擇PNP型的接近開關。 3、2、系統程序設計
PLC控制器的程序設計重點和核心是圍繞着酒缸的旋轉速度控制和酒缸上60個瓶位相關位置的檢測移位、破瓶、空瓶瓶位相關位置的檢測移位和相關灌裝閥等的控制。其中的瓶位移位檢測程序中，採用了三菱PLC位左移指令。
瓶位移位檢測，採用PLC位左移指令，這條指令是整個子控制程序的核心之一，主電機和瓶位檢測開關同步檢測移動的酒瓶，主電機每轉一週，正好對應酒缸轉過一個瓶位，PLC內部單元內對應這60個瓶位的單元爲M500~M559，單元個數用第一個字母K設置爲K60，每次變化一位用第二個字母K設置爲K1，M50反應了瓶位的空、缺位置，並將檢測到的這個位置以電機轉速的頻率移位下去，在內部相應的單元內置"1"或"0"，控制相應的閥門和攪拌瓶蓋的電機的開與停。系統在連續檢測90個空瓶位後,停止攪拌瓶蓋的電機的運行,檢測瓶位的個數可以根據用戶的要求任意設定。
出瓶位檢測。迴轉酒缸通過壓力往瓶內背壓裝酒的過程中，空瓶在背壓後,可能由於瓶子本身裂紋等原因導致突然爆瓶,這就需要檢測出爆瓶瓶子的位置,在這個瓶位的位置進行打開吹掃電磁閥,噴出壓縮空氣,將瓶位上的碎瓶片吹離位置,在連續吹掃幾個瓶位後,在打開噴射電磁閥,噴射出高壓水注,在對破瓶位置周圍瓶位連續噴射幾個瓶位。
破瓶檢測和瓶位檢測開關同步檢測移動的破瓶，主電機每轉一週，正好對應酒缸轉過一個瓶位，PLC內部單元內對應這20個破瓶位的單元爲M600~M619，單元個數用第一個字母K設置爲K20，每次變化一位用第二個字母K設置爲K1，M52反應了破瓶的位置，並將檢測到的這個位置以電機轉速的頻率移位下去，在內部相應的單元內置"1"或"0"，控制相應的噴射和吹掃電磁閥開與停。連續噴射和吹掃電磁閥的開聽、停時間可以根據工藝要求任意設定。
系統自動化運行可靠的保障就是控制進出瓶蓋的同步跟蹤，既準確檢測電機轉速檢測開關、破瓶檢測開關和進瓶檢測開關三個條件。
970GOT人機觸摸屏操作終端機的軟件採用三菱公司的GT WORKS軟件包，其中GT Designer是一個用與整個GOT9000系列的繪圖套裝軟件。該軟件包操作簡單，事先可在個人計算機上組態並仿真調試，完畢後下載至人機操作終端機。同時，因爲人機界面又具有觸摸屏的作用，將常用的開關設在顯示屏上，方便操作。還可並以增加一些功能，如設置報警信息等。
4、改造後控制系統功能
系統正常運行時，機器爲自動控制，根據進出瓶帶上瓶的滿缺，按設定速度或慢速運行，進瓶檔瓶，無瓶不下蓋，爆瓶自動沖洗，灌裝位置自動背壓，下蓋輸蓋系統的自動開停和安全保護等動作的協調聯鎖。原來所有按鈕的操作改造後都在觸摸屏上進行。
5、控制系統檢測狀態的監控功能
進瓶檢測開關和破瓶檢測開關通過檢測每個壓瓶部分上面的小鐵片的位置，產生光電脈衝輸出，再有PLC採集，由於每個壓瓶部分上面的小鐵片的位置是活動的，在機器運行一段時間後，壓瓶部分上面的小鐵片和檢測開關的位置發生位移，造成檢測開關誤判斷，如沒瓶判斷爲有瓶，爆瓶漏檢、誤檢等造成輸出失誤，使PLC產生誤動作，造成如背壓、爆瓶吹、洗、瓶蓋攪拌系統控制失靈等故障現象。
在改造前的日常生產過程中，碰到這種現象時，操作工只能將各個功能開關或按扭打到手動控制檔位，使機器設備工作在無監控狀態下，機器失去自動控制功能。造成了很大的生產原料如氣、水、酒的浪費。只能在生產的間歇，才能由維修鉗工和電工根據檢測開關上的小發光二極管的亮和滅通過調整位移距離只有5~8mm的檢測開關的安裝位置，來修正檢測開關和小鐵片的間隙。這種檢測手段非常落後，調整後的效果反應致後，不能及時反應調整結果。
針對這種檢測狀況，結合改造後的灌裝、壓蓋機控制系統的配置，新增了這部分檢測功能，並集成在人機觸摸屏中，完成瓶位檢測。
在人機觸摸屏的界面分頁顯示屏上，可以分別時關、攪拌電機等電磁閥的開關狀態都以不同顏色來顯示，非常直觀。
增加這套系統功能的是爲保證灌狀壓蓋機的自動化控制系統正常運行而專門設計的。
6、結束語
改造後的控制系統大大地簡化了複雜的機械結構，經現場運行情況和控制效果檢驗，系統的自動化程度達到了設計要求，大大減少了操作人員的勞動強度，使啤酒灌狀的日產量比過去提高30%以上，故障率大大減低。體現了現代設備的自動控制技術。是在消化、吸收當今工業控制的先進技術的基礎上加以創新、研製而成的目前國內技術最先進的灌裝控制系統。
