The cement production line control system based on ABB AC500 PLC

The cement production line control system based on ABB AC500 PLC (ABB China) Co. , LTD. , the low pressure of welcome to visit e hall hall 10 building materials machinery exhibition hall cement equipment, baking-free brick machine/brick making machine, block molding machine, glass production equipment, tube machine, cement. 。 。 With the rapid development of China's economy, the demand for cement growing in all walks of life. Major cement companies at home and abroad to build a large dry process rotary kiln cement production line in China, it provides unprecedented opportunities for development of cement industry. ABB has prepared the best for cement production line of industrial automation solutions, help build has the international advanced level, high output, low consumption, environmental protection and efficient production line. Cement production technology briefly, in general, the cement industry production of Portland cement, Portland cement is a kind of usually gray fine powder, it is composed of calcium ( From limestone) , silicate and aluminate ( Clay) And the composition of ferrite. In a silicate cement plant, cement production technology is the main process of the raw material crushing grinding is made after, and then put the raw materials to the high temperature furnace with fuel to mature, the material will finally made cement clinker and gypsum mixed grinding fine, need after mining, raw material crushing, the clay to dry,, clinker calcining, clinker cooling of raw material grinding, cement grinding and finished product packaging process, as shown in figure 1. Figure 1 cement factory of typical production process all in all, its production process is usually can be summarized as 'three grinding a kiln', can be divided into the production of pulverized coal preparation, preparation, clinker calcining and cement grinding and factory four steps. 1. Raw meal preparation will calcareous raw materials, clay raw material with a small amount of correction after crushing the raw material according to certain proportion coordination, fine grinding and mixing of raw ingredients, uniform quality of right. 2. Raw cement calcining the coal, the pulverized coal preparation must be preparation of pulverized coal, coal combustion granularity, required by the offer so that the full combustion, sufficient combustion reaction ability. 3. The diameter of the clinker calcining clinker spherical agglomeration must be 3. The range of 2 ~ 50 mm, they are between raw materials produced by chemical reaction. Put the raw material in cement kiln calcination to partial melting for Portland cement clinker, and stored to clinker silo. 4. Cement clinker grinding and factory will be adding suitable amount of gypsum, common ground for cement mixing materials or additives, and packaging factory. Grinding process in a closed system, the system is equipped with an air separator, used to separate cement particles by size, not completely fine grinding material is back into the system. Design and analysis through the introduction to the technological process, it is not hard to see this is a typical sequence control engineering ( Storage of raw materials, transportation, Cement grinding - Cement outbound and packaging systems) 。 We can through to the control object - — The operation of the equipment, motor start, stop, and in turn positive &negative control, as well as a variety of alarm indication, switch signal and analog signal acquisition and programming processing to realize the automation control of the process. Production line main equipment control, monitoring, alarm and print report management functions such as carrying out is controlled by the computer, control hardware preheater and kiln head of distribution in the grinding of raw materials, process of three field station, process station and is controlled by a data communication system between provide two-way information processing and information transmission. Divided according to the requirements of control, the main features include: data acquisition function, the switch quantity control function and sequence control function. Composition of the system configuration system including process control stations, operator station and engineer station and communication system ( Modbus，ProfiBus DP/PA） 。 The function of AC500 PLC flexible and scalable. Traditional small, medium, and large hardware and software of PLC controller product difference is very big, the expansibility of system is very limited. The AC500 only by 3, 4 kinds of different memory and speed of the CPU central processing unit can realize system comprehensive upgrade, so that can protect customer's existing investments. The control system of network principle is shown in figure 2. Figure 2 cement plant the principle diagram of the control system network of cement production is extremely scattered, each control station of the system safety greatly depends on the stability of the control network. Redundant optical fiber ring network technology design and process control network for highly reliable, greatly improved the safety factor of the whole system. 1. The first level - — Monitoring of management by the central control room operating station and engineer station. Selection of industrial control computer, an industrial Ethernet and TCP/IP communication, PLC system centralized control. Through the industrial control configuration software real-time monitoring process parameters change, the whole line equipment operation and failure, etc. , at the same time is responsible for the daily report printing, accident type and data record, etc. 2. Level 2 - — The scene of the process control by each subsystem or complete sets of equipment control system implementation. With the AC500 PLC controller system as the control core, according to the substation ground configuration. Place through FBP distributed extended I/O communication of flow, pressure, temperature, motor parameters such as acquisition and control. 3. Level 3 - — Electric control system of single local control by field. Adopting ABB S500 series products of distributed I/O, collecting field parameters, the execution of the higher level PLC main control command. Conclusion on the basis of the results of the technical scheme, has been in a cement production line in shanxi concrete implementation. The adoption of computer control technology and PLC control technology with the combination of methods, greatly improve the production efficiency of the cement production system, reduce the labor intensity of workers, improve the level of the automation management system, effectively prevent the occurrence of the person accident, also save a lot of money for the company.
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