Practical PLC programming (Book 1) Vibration analysis Functional and Vibration Diagnostics Indirect Parameters in control Product tracking in packaging Vladimir GoudimaTable of Contents Preface Vibration analysis Introduction Formulas and meanings of vibration cere Vibration graph (function of time and frequency)... Vibration wement hardware... Accelerometer... Functional diagnostics. sac Dust Collector Diagnostics 0... Defect #1 - hole in the dust collecior filter. Defect #2 — permanent air loss in the dust collector. Defect #3-Fil m in lector. Cellulose conveying system Diagnostics rithm umeters development Parameter V1 (vacuum at the filter ) . ‘Parameter P1 (Pressure between Fan and Dust collector). Diagnostics table Example of the diagnostics PLC program (Fault generation)... 5S HML alarm programming (Rockwell software ®, Factory View Studio ME ®) ..57 lulose Feeder Diagnostics Indisect Parameter. Int n.. ‘Nalamycin addition... Dry mixer... Formal Formulas. ‘Machine Configuration: Variant 0... Vladimir Goadima, Practical PLC programming. Book 1 ARelation between Cheese flow and Motor current... Experiment...., . TEENGS os oensnernesene Motor Current separation Product tracking... . Vladimir Goadima, Practical PLC programming. Book 1 4Preface Programming applications, discussed in this book: Vibration analysis, Vibration diagnostics, Functional diagnostics, Indirect parameters, Product tracking in packaging The purpose of this book is the attempt to familiarize industrial programmers with the application specific meanings, approaches and programming methods. Vibration analysis is the set of tools to convert mechanical vibration to the electrical form, measure it, digitize, perform mathematical operations and produce data. Vibration diagnostics is set of methods to detect defects using data from Vibration analysis, Functional diagnostics in this book is the set of methods and approaches to detect defects and pre-defect conditions on the base of commonly used operational parameters (pressure, current, temperature). In some sources term “Functional diagnostics” means diagnostics based on the analysis of machine ability to perform its functions, Indirect parameters. In this book we refer parameter as indirect, if it can be measured. and used to evaluate another parameter (direct parameter), that cannot be measured, but needed for the control, Direct parameter may be a function of more that one indirect parameters. For instance vibration level (indirect parameter) of the machine base may give value to the direct parameter (machine stopped, running idle, running loaded), Product tracking is the attaching and using updated data for every piece of product at any point of the manufacturing process, Usually the product tracking system includes product identification devices, media and programmed methods (using barcode, RFID, OCR), updated data structure attached to every product ID; part of the PLC program to update data structure; Virtual conveyor (in PLC program) synchronized with the real conveyor carrying product items. Every chapter of this book devoted to certain application and has the introductory part. Vladimir Goudima. Practical PLC programming. Book 1 5PLC program examples developed using the Rockwell Automation products. Controllogix ®, RSLogix5000®, RSLinx ®, and FactoryTalk ® View Studio Machine Edition. Link: wavvcrockwellautomation com Materials, examples, programs and diagrams in this book are included solely for illustrative purposes, inno event will Author be responsible or liable for direct, indirect or consequential damages resulting from the use of described materials, examples, programs and diagrams Reproduction of the contents of this book, in whole or in part, without written permission of Author is prohibited Vladimir Goudima. Practical PLC programming. Book 1 6Vibration analysis Introduction In this chapter we will discuss basic meanings of the vibration theory and applications, practical approaches and programming for the control systems, Vibration control is a popular and effective method for the non-destructive diagnostics of the variety industrial devises. The predictive and preventive maintenance systems mostly rely on this method This fact also means the industrial programmer sooner or later will deal with those systems in new projects, orin some sort of modification and fine tuning, adding features to the existing hardware and software. Many vibration analysis equipment vendors are on the market for a long time. They provide reliable methods, devices and software, Some devices are hand-held; the others are permanently installed as part of the machine. They may employ self learning algorithms, sophisticated mathematical and statistical methods, be in a network, and be accessible from intemet. Date should be available 24*7 including data from non user-friendly locations such as remote gas-oil pipes and pumping stations, places with elevated noise, temperature, biohazard and radiation. Modern diagnostic systems may suggest corrective actions, evaluate the time to the failure, and send notifications and alarms to HMI, e-mails, SMS. Vibration control systems work mostly in three frequency diapasons Infrasound (0-20 Hz) tank and big chambers oscillations, ventilation systems, some liquid flow applications, slow rotation of big masses (power generation); Sound (20-16 kHz) motors, bearings, gears, fans, conveyors, pumps; Ultrasound (16 kHz and more) air leak in vacuum chambers, cavitation, material destruction (bearing, tank walls, machine parts) Vladimir Goudima. Practical PLC programming. Book 1 7Vibration is the cyclic material displacement caused by various forces Those forces may be caused by the unbalanced rotating masses, interactions between good and defective machine parts, material flow and damage. Vibration carries information about the object conditions, existing and developing defects. There are methods to measure and analyze vibration parameters to get information about current machine condition and predict future events. In some situations vibration control may be combined with temperature measurements Vladimir Goudima. Practical PLC programming. Book 1 8Formulas and meanings of vibration analysis ‘The unbalanced force of the rotating part Mass = “m” Radius =“r" F — Force of inertia F= m*r*o**2, Fe m*r*(2zf); f= cycles per second; Where **2— ~in power 2, r-radius; Vibration Displacement Maximum Vibration Displacement - Amplitude: Xmax; [mm, inch, mils]; Vibration Displacement for the sinusoidal waveform x(t)=Xmax * 00s ( 2aft ~ x) Vibration Speed W(t x(t)/dt, [ */sec];, Vibration Speed for the sinusoidal waveform: Vladimir Goudima. Practical PLC programming. Book 1(t)={ 2nft)* X*cos(2nfi-(p_x-n/2)); Vibration Acceleration a(t)=dv(ty/dt, [*(sec)**2], Force caused by vibration F(=m*a(t); [Lb, n, ke} Root mean square is a value reflecting the energy of vibration. RMS (root mean square) may be for the sinusoidal and non-sinusoidal vibration: X_ams = V¢(I/T)*IEx(Q)#2*dt}; ‘Measured Peak value for sinusoidal and non- sinusoidal signals: a Peak value [Peak to peak max i (time) Test time Calculated Peak value for the sinusoidal and non-sinusoidal signal: Vladimir Goudima. Practical PLC programming. Book 1 10Xmax = X_rms * V2: Vmax = V_rms*V2; Amax = A_rms*V2; For the sinusoidal signal calculated and measures peaks are the same For the non-sinusoidal signal the measured and calculated values a different. Vibration spectrum is the vibration parameter (x,v,a) as a function of frequency; CPM — cycles per minute, Frequency ~ cycles per second; Vibration Waveform - is the vibration parameter (x,,a) as a function of time; Vibration graph (function of time and frequency) Vibration parameters are often represented graphically as function of time. Magnitude in mm or Inch; Speed in IPS, mm/sec, VdB, Log IPS; Acceleration jn gs inches per second: Vladimir Goudima. Practical PLC programming. Book 1 uEvery defect generates vibration at certain frequencies, This means the possibility to discover defects, if the time based sequence - Waveform (Amplitude (t)) will be converted to the frequency based distribution — set of harmonics (Amplitude (f)), In his case the position of the vibration speed peaks will pinpoint existing defects One of Fast Fourier Transform (FFT) methods used to convert a time based vibration (Waveform) graph in to the frequency based distribution (Spectrum), To use this method the continuous Amplitude (#) sequence modified into the periodical applying the correction window (type: Hanning, Hamming, Rectangular, Flat Top, Kaiser Bessel, Bartlett, Gaussian, etc). xya xv.a \ % 4 2 ‘Window Where: x(t) vibration displacement, v(t)- vibration speed; a(t)— vibration acceleration; Every correction window type has its own pros and cons. Really programmer does not need to go deep with this math on the first stage. The type of correction window is one of configuration parameters to select during device setup. Usually is good enough to follow manufacturer's guidelines However the deeper knowledge, the better system performance may be achieved. Vladimir Goudima. Practical PLC programming. Book 1 12Other configuration parameters needed for math calculations are: FMIN Hz minimum frequency for FFT; FMAXHz — maximum frequency for FFT, Frequency Span= FMAX-FMIN; LineNumber number of lines (number of harmonics in FFT). This means that the real waveform will be approximated by the sum of LineNumber sinusoidal signals. Every sinusoidal signal has its own amplitude, phase, and frequency. (FMAX-FMIN)/ LineNumber = Hz/Line, Spectrum has parameters: Amplitude (Vibration) Frequency (Hz, KHz, CPM, CPM* 1000, Line number). Phase Additional information may be obtained from correlation between Vibration waveform and tachometer angle for rotation parts Vladimir Goudima. Practical PLC programming. Book 1Vibration measurement hardware Vibration acceleration measured by the sensor - accelerometer. ‘The acceleration of the sensor seismic mass generates force F(t)=m*a(t) This force applied to the Piezo-crystal. The Piezo-crystal deformation generates electric signal proportional to the vibration acceleration. ‘The analyzer calculates values for the PLC: integral of acceleration is the vibration speed. The integral of the vibration speed is the displacement. Accelerometer types — piezoelectric, piezo-resistive, capacitive Accelerometer may have 1, 2, 3 axis and installed to measure vibration in corresponding axis. Accelerometer Terminal Box Load spring Seismic mass eon Piezocrystal <————Mounting part Vladimir Goudima, Practical PLC programming. Book 1 4Vibration control system HMI Data Server Plant Ethernet Network nalyzer module nodes Ne Proprietary Network ‘Commutations “ ‘Thermocouple } Accelerometer Accelerometers and thermocouples installed on machines and wired directly or through commutations to Analyzer modules on the proprietary and common networks (DeviceNet, ProfiBus, EtherNet, ModBus, ete...). Analyzer module is a separate controller with builtin mathematical calculation functions, network features and possibility to read/write configuration parameters and vibration analysis data It collects data from accelerometer, performs FFT and averages data (Displacement, vibration speed and acceleration for every line of spectrum or for a spectrum diapason) Data are stored in the Analyzer memory and been read by PLC. Usually the Analyzer is quite expensive, so possible to use commutation and sequentially connect different accelerometers to the same Analyzer. Vladimir Goudima. Practical PLC programming. Book 1 15aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Every point ~ all parameters for every spectrum diapason, current and calculated statistics for 1un and idle modes in table form with color animation, to detect deterioration and improvement Every point - all parameters for every spectrum diapason, current and calculated statistics for run and idle modes as combined bars, Every combined bar consists of 3 animated (fill up) bars ‘Averaged Vibration in Run mode; Averaged Vibration in Idle mode; Actual Vibration Every unit drawing with feature to display parameter of the operator choice (by touching the point of interest and using a drop down menu to call a pop up window inside the opened window). Possibility to display trend of any parameters for any point of any unit for any mode (Run, Idle). Possibility to enter alarm limits (with the password) and descriptions, notes by the operator, mechanic, electrician, engineer. Description may be removed with the password only 18. Operations on big multidimensional files in the PLC may increase program scan time and be the cause of the major fault. During this operation data from every position are copied to the next location within the single program scan. ‘There are 2 ways to avoid major fault Perform one data move per one program scan Change file index instead data moving with the same index. PLC Data structures User Defined Data type: Unit Name to handle names and vibration diagnostics configuration according to the Unit Number Vladimir Goudima. Practical PLC programming. Book 1 23aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Sytner spicy if grafts. eee Oe roeommccenpe ee soneaarocesngs RO3_Cale_SBR_ In this subroutine calculated the averaged values for all parameters belonging to the single point of measurement. om nero) | cet Pras 4 33. ia seme | a, —— Vladimir Goudima, Practical PLC programming. Book 1 4lSees eearene | ie a ——— Dest prac era Bass mommy sae pw | a ck repens ee oes reas heen rrtgnenet come eet ‘rca mernuneye | ot raven | a vases ie, ‘Sac a, Potmtunades 6 = a ee es mat een uneven | —| ee Ss om ver Unni Vladimir Goudima, Practical PLC programming. Book 1rm) fa ae oe al te) Be Vladimir Goudima, Practical PLC programming. Book 1 43HMI screen Ranges: R1, R2, R3, R4, (RI contain BSF; R2 contain BPFO; R3 contain BPFI; R4 contain TPT), “Nan Evinratien _ Vibration Analysis | PO bat pass hogy atorace PFI ballassRequency, merce ae BSF bal in fouerey ‘TFT indumertl rae feu tec ineraid Vladimir Goudima, Practical PLC programming. Book 1 44Functional diagnostics Functional diagnostics uses conventional parameters to detect existing or coming failure or a machine defect We will develop a diagnostics PLC program for the Cellulose delivery system, used in a shredded cheese packing, Description of the Cellulose delivery system Cellulose added to the shredded cheese to prevent cheese flakes sticking. Cellulose delivery system is the combination of well known in many industries applications Pneumatic conveying system, bulk dispensing system and Dust collection system Pneumatic conveying system delivers Cellulose; Bulk dispensing system provides proper cellulose dispensing; Dust collection system collects Cellulose from the conveying air. Vladimir Goudima. Practical PLC programming. Book 1 45Cellulose delivery system Cellulose bag (tote) Dust Separator __Air / Cellulose Separator Cellulose and air mix Rotary valve Valve —— Seale—_ Vibrator—__, Valve = / ‘ Cellulose Feed screw collection Vladimir Goudima, Practical PLC programming. Book 1 46Cellulose shipped to the plant in a bag having cubic form - tote. The special hoist places tote in the tote unloader. The bottom part of the tote has a sleeve that may be directed to the hopper below. Set of devices to transfer bulk product from the hopper to the horizontal pipe sometimes called Eductor This is a fully controllable device with all required interlocks The air flow in the pipe creates a Cellulose-Air mix and brings it to the Cellulose-Air separator, where Cellulose separated from air and drops to the hopper The cellulose collected on the bottom of the Cellulose-Air separator and through the rotary or other controlled valve drops to the screw feeder hopper. The pressure in the cellulose air conveying system is below the pressure on the exit from the screw feeder. The rotary valve or system of 2 (NO-NC, both closed before any valve opening) valves provide the bulk transfer without air flow from high to low pressure areas, This feeder stays on the scale and provides cellulose dispensing according to the demand from the control system. The feeder screw rotates and cellulose transported to the point, where the screw ends up. If the bulk product has excessive humidity, the cellulose may not freely go to the feeder screw. Instead it creates the “arc” in the hopper. To overcome this problem used pneumatically driven vibrators, mounted on the outer surface of the feeder hopper. Sooner or later the feeder hopper need the refill. At this point the conveying system starts and cellulose delivered to the feeder hopper. The cellulose conveying ends up, when the feeder reaches the preprogrammed weight. There are two things to mention to complete the bulk conveying system description: 2. Conveying system stop procedure ~ should automatically stop the cellulose delivery from the tote to the horizontal pipe, ran air threw the system for the time enough to remove all bulk product from the pipes. Immediate system stop without this procedure is the shortest way to block pipes with bulk product b, The weight system calculates the amount of the cellulose delivered to the shredded cheese using so called loss in weight method, With this method the amount of the cellulose dispensed equal to the difference between hopper weight before and after dispensing. If during dispensing the hopper refill starts, the dispensed amount calculated assuming constant feed rate, i.e volumetric approach. The feed rate multiplied by time and the result is the amount dispensed. The air, separated from cellulose in the Cellulose-Air separator transferred by the fan to the Dust separator where dust separated from air and air returned to the atmosphere. The Dust separator consists of a chamber with filter set on one side and the bottom formed to collect bulk. The pressure forces air threw the filter, leaving dust particles on the surface. Vladimir Goudima, Practical PLC programming. Book 1 47There are 2 types of dust separators: automatically cleaned and manually cleaned In the manually cleaned Dust separators the maintenance person changes filters. Filters changed on the base of difference in pressure gages readings inside and outside the chamber. The criterion is the differential pressure value. If this value is equal or exceeds the limit value, the filters have to be changed. Otherwise the air flow in the conveying pipes drops and bulk product plugs pipes Programmer should know that for some products, the raise of the air humidity will cause the growth of the differential pressure in partially plugged filters. This may happen during night break or equipment sanitizing, So the morning equipment start or start after sanitizing may bring surprises In the automatically cleaned Dust separators the filter made in the form of bag, where the air flow directed from outside the bag to inside, So the dust deposited outside the bar and the inside bag part connected to the atmosphere. There isa special air nozzles positioned inside the filter bag. The pressurized air periodically blowing through those nozzles and the dust deposits outside the bag drops down and collects on the bottom of the main chamber The main chamber bottom has a shape to collect dust in the central part. The feeding screw positioned there to move the dust to the outlets. Every outlet has a rotary feed valve to drop dust to the collector bin without releasing the pressurized air from the main chamber. Dust Collector Diagnostics There are many processes dependable from each other are going in the Cellulose delivery system, The information about those processes is available for the PLC logic in the form of the process parameters (Analog and Digital inputs). Defects in the equipment or some conditions and parameter combinations may have a destructive influence to the provess, i.e. may stop the system or make it dangerous in some way, Some defects and problems leading to defects may be detected on the base of the parameter analysis, The part of the PLC program, dedicated to the detection of the defects and conditions leading to defects usually has name “Diagnostics” This type of programs as an effective tool in the equipment reliability, availability and maintenance cost reduction, will have an enormous growth in the nearest future Vladimir Goudima, Practical PLC programming. Book 1 48The Diagnostic logic in this book uses process description, defects and problems description, relations between defects and parameters. Defect #1 - hole in the dust collector filter ‘The filter bag may have a hole. In this case we the dust is going outside without filtering, There are 2 parameters to control for the problem detection: Parameter 1: Pressure variances The Pressure changes inside the main chamber. Some changes are normal; some caused by the defect. The pressure variances will depend on the size of the hole and a variety of other parameters, Mostly it is a very complicated task dependable of the exact process and equipment. If the hole appears momentarily, then need to control a pressure change inside the chamber for the moments excluding the air cleaning pulses, In any case have to calculate a normal pressure value using statistics, modeling and compare this value to the actual pressure, Certainly not every size of the hole may be detected this way, However, his is the cheapest approach, all equipment already installed. The task is to do the program smarter. Parameter 2: Particle detection The result of the hole in the filter bag is the dust escape to the atmosphere. To detect this dust we have to know its properties and install proper sensors in proper places. For instance in some cases it is possible to detect particles in the air by measuring the capacitance of the filtered air or an optical characteristics, or use chemical detection sensor. Possible non expensive approach may be realized on the base of retro reflective polarized photo sensor. If its beam positioned across the filtered air exhaust, the reading is the air transparency dependable and consequently depends of the dust particles presence. In other words the dust in the air closes sensor. Defect #2 — permanent air loss in the dust collector The pressurized air system dispenses air all the time due to the broken pipe or a faulty solenoid valve. In large systems with 2” air pipes it may be the source of significant energy losses There are as minimum 2 parameters may be controlled to detect the problem: Parameter 1: The compressor restart frequency It isa good idea to program some code and compare actual average time between the compressor restarts and the same time between restarts for the well-functioning system. Usually this time varies through the day and operation mode, so code in the PLC program should act accordingly. Vladimir Goudima, Practical PLC programming. Book 1 49The result should be the informative message of other actions. Sometimes the new equipment installation or problems with existing equipment may generate alarm in this case, However you have a warning and after that need to understand — what is going on and perform necessary actions Parameter 2: Vibration and noise This diagnostics method based on the fact, that the released pressurized air (also liquids at cavitations) generates an ultrasonic frequency. Definitely this approach needs additional equipment, however this method is very effective. The PLC code may compare the normal ultrasonic air vibration level to the actual noise and generate some alarming actions (Informational messages on HMI, Alarm messages, Sound and visual alarming) Defect #3-Filter bags are plugged in the dust collector The simplest way is to control the difference between pressure in the main chamber and atmosphere When this difference reaches the programmed preset, the lari actions should be generated Cellulose conveying system Diagnostics Algorithm and parameters development The conveying cycle should begin and end with the system running without cellulose, i.e. with the air only. This will remove deposits from pipes. Let’s name system parameters as “NORMAL” for the fully functional Cellulose conveying system at a cellulose delivery cycle Before using the meaning Vacuum, let's be sure to completely understand this meaning For the point of measurement #1 the Pressure is Pressurel, the Vacuum is Vacuum, the atmosphere pressure is PressureATM. The formula to calculate the vacuum is This means the more vacuum, the less pressure Vladimir Goudima. Practical PLC programming. Book 1 50aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for 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