CONTENTen.famsungroup.com/Upload/201902/20190221155323_6926.pdfsingle-machine is divided into the...

Operation Manual of MyCos v2.0 System

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CONTENT

1. General .................................................................................................................... 1

1.1 Briefing of the system ....................................................................... 1

1.2 Operating environment ..................................................................... 1

2. Starting of work sections ................................................................................... 1

2.1 Test run mode ...................................................................................... 1

2.2 Auto mode ............................................................................................ 2

3. Briefing of batching function ............................................................................ 3

3.1Formula .................................................................................................. 5

3.3Create formula ...................................................................................... 6

3.3Download formula ............................................................................... 9

4.Parameter............................................................................................................... 11

4.1Batching parameter .......................................................................... 11

4.2 Screw feeder parameter ................................................................. 12

5.Alarm Record ........................................................................................................ 12

6. Run chart .............................................................................................................. 13

6.1 Run Chart of weighing instrument .............................................. 13

7. Reports .................................................................................................................. 14

7.1 Formula Report(detail) .................................................................... 14

7.2Formula Report(total) ....................................................................... 15

7.3Material Consumption Report ........................................................ 17

7.4Batching Production Report ........................................................... 18

8. Control of hammermill ...................................................................................... 21

8.1 Control interface ............................................................................... 21


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1. General

1.1 Briefing of the system

In general, the feeds can be produced in the divided work sections, such as feeding,

grinding, proportioning, pelleting and extruding work section. Each work section contains

grinder, mixer, pelletizer, extruder, etc. Wherein, the proportioning work section is the key

of the feed production process and also it is the most complex part. This system is

developed based on TIA portal, WINCC and Visual C Language, and it can complete the

control and management of all the production processes and equipments of the general

feed mills. Especially, the proportioning work section control can help the user to establish

and manage the formula, and also the user can use this system to freely arrange the

production tasks based on actual demand. The data in the production process will be

stored in this system for the user to access, so this system can provide the data basis for

the user to improve the production management level.

1.2 Operating environment

The system should run in the following two environments:

(1) Hardware environment

CPU of computer: Intel Pentium 4, primary frequency more than 2 GHz; working

memory more than 4 GB; hard disk more than 500 GB;

(2) Software environment

Operating system: Windows 7 Professional or Windows Server 2008; lower computer:

Siemens TIA portal V13 SP1; upper computer: Siemens WINCC V7.3; database: SQL

2008 R2.

2. Starting of work sections

All feed processing sections have the same starting process, the start mode of the

single-machine is divided into the Test-Run mode and the Auto mode, and the two start

modes are introduced as follows.

2.1 Test run mode

Click on the device screen to pop up the motor start screen as shown in Fig. 2.1. The

blue title bar shows the motor number (motor is M44 in Fig.), the red solid line box shows

the motor alarm, and the yellow light indicates that this motor is at the alarm state. Keep

the mouse on the red light, which will show the alarm type of the motor. In the Test-Run

mode, you can ignore the yellow light alarm. However, red light indicates the state of


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severe alarm. And the motor can be started only when all other warning lights are at the

off state.

Fig. 2.1 Start screen of motor

Click the mouse to select the “Test-Run” option, the motor can run in the Test run

mode. In the Test-Run mode, click on the "Start" button, the motor can be started, if there

is the feedback signal within a few seconds after starting up, the motor screen will be

changed to green. If there is no feedback signal within 3 seconds (or 30s for star-delta

start), the motor screen will display the red flashing and give an alarm at the same time,

which shows that the motor fails to be started normally. After the motor is started normally,

click on the “Stop” button to shut down the motor.

Fig. 2.2(a) Motor under Auto modeFig. 2.2(b) Motor under Test-Run mode

2.2 Auto mode

Click on the "Auto" option in the screen of Fig. 2.1 (see Fig.2.2), the motor can enter

the Auto mode.In the Auto mode,all machines are interlocked, and user can automatically

start all the equipment back-to-front in a certain route, or start/stop per process section

through selecting the routine selection button as shown in Fig.2.3.

Fig. 2.3 Route selection dialog button

In the control page (see Fig.2.4), select the source bin, the destination warehouse,

the the corresponding startup routine in turn, and click “Start” button, the machines will be

started one by one back-to-front.When stop the production processes, click “Stop”

button and the machines will be stopped front-to-back one by one. If it is necessary to

pause the start/stop process, clock “Pause” button. If it is needed to record the

material volume of bins, input the weight of material to be dumpedin the green text

box, thesource bin will automatically be reduced by corresponding weight, and the

target bin will be added with the same weight.

Failure alarm indication

Auto/Test-Run selection


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Fig. 2.4 Start/Stop routine control

3. Briefing of batching function

All the functional buttons of the proportioning system are arranged above the

operation interface, as shown in Fig. 3.1; name of the buttons: batching, formula and

parameter.

Fig. 3.1 Function button arrangement of the system

Enter the batching screen shown up (see Fig.3.2).

1.Source bin selection

2.Target bin selection

3.Routine selection

Accept weight 4.Start/Stop selection


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Fig.3.2 Batching screen

Fig.3.3 Batching scale

Batching task

Control button

for batching

Mixer info

Reading of

instrument

Actual discharge weight

Theoretical discharge

weight

Alarm info of scale Batching completing indicating light,

click the light during production will stop

batching process.

Red light indicates

that the bin is

activated for batching.

When bin lack of

material alarming,

click on the light to

discharge another bin.

Click “Skip” to discharge the next bin,

and when completing discharge tasks

of following bins, the discharge of

the skipped bin can be continued.


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Fig.3.4 Control buttons for batching process

3.1Formula

Click on “Formula” button to display the Formula Management screen (see Fig.3.1.1).

Fig. 3.1.1Formula Management buttons

Fig. 3.1.2Raw material management

Start batching task button.

Capable of download any new

task to start batching process

once the previous batching task

completed.

Pause

Batching

button

Button inactivated: execute

batching task for a single

batch; Button activate:

execute continues batching

task

Auto Batching button. If it is inactivated, there will be no

batching production. If it is inactivated during batching,

the current bin will not discharge until it is activated

again.

Auto Batching button + Skip button can manual control

the batching operation of a single bin.

Stop Batching button.

Pause Batching + Stop

Batching to end batching

process.

When batching error

alarm, click on the button

the clear alarm and reset

Operations of

Add or Delete,

Modify raw

material

(Fig.3.1.2)

Operations of Add

or Delete, Modify

formula (Fig.3.1.3)

Change the

material name of

bin; set material

weight of bin

(Fig. 3.1.4)

Real-time data of

batching process

Raw material list

Import raw material name

in formula name

Operations of

Add or Delete,

Modify raw

material name


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Note: Raw material that already created in formula could not be deleted unless the

formula is deleted.

Fig. 3.1.3 Formula Management

Fig. 3.1.4 Bin material management

3.3Create formula

1. Click title Edit Formula >Create, and input formula information into window of Fig.3.2.1

(click Enter key to confirm).

Formula

information

Create/Modify/

Delete formula

Create/Modify/

Delete formula

details

Copy/Downl

oad formula

Formula list

Bin raw material management

Bin list

Activate

control


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Fig. 3.2.1 Edit window of formula

2.Click title Edit Formula >Create, and Fig. 3.2.2 appears. Select corresponding material

items and input the percentage of this material in formula, click Create to confirm.

Fig. 3.2.2 Formula material editing window


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3. The material selected will appear in Formula Composition window (see Fig.3.2.3),

continue and repeat above said step 2.

Fig. 3.2.3 Window of raw material in formula

4. When the sum of percentage is 100%, click Edit Formula >Save to complete the

creation of new formula(see Fig.3.2.3 and Fig.3.2.4).

Fig. 3.2.4 Sum of percentage


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3.3Download formula

1. Select the corresponding formula in the formula list (see Fig.3.3.1). Click on button

“Download Formula” (see Fig.3.3.2), and a dialog box pop up (see Fig.3.3.3). Enter batch

number into the Batch No. text box. click Accept to download the formula to PLC system.

The formula detail will be shown as Fig. 3.3.4.

Fig. 3.3.1 Formula list

Fig. 3.3.2 Button of Formula Download

Fig. 3.3.3 Editing window of Batch No.


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Fig. 3.3.4 Formula details

3.If error occurs during download, error information will indicate below the percentage

area (see Fig. 3.3.5) and help to find out the error of formula.

Fig. 3.3.5 Indication of formula download error

4.After completing download, click Start button on Batching Screen (see Fig.3.2) to start

batching process.


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4.Parameter

Click on Parameter button (see Fig.4.1).

Fig. 4.1 Button of Batching Parameter

4.1Batching parameter

For batching parameter, see Fig. 4.1.2.

Fig. 4.1.2 Batching parameter

Batching Parameter Screw Feeder Parameter

Weight per batch

Parameters of

batching scale

Parameters of

mixer

Batching alarm.If alarm

during batching, it will be

automatically cleared.

Over time of liquid

adding


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4.2 Screw feeder parameter

For parametersof screw feeder, see Fig. 4.2.1.

\

Fig. 4.2.1Screw feeder parameter

5.Alarm Record

Click on button of Alarm List (see Fig.5.1), and the Alarm Record page (see Fig.5.2)

will show up. And corresponding record will also show up on the header of the system

(see Fig. 5.3).

Fig. 5.1Button of Alarm List

Fig. 5.2Alarm Record page

In-fly weight adjusting

button, the in-fly weight

can be adjusted

automatically before each

batching production.

In-fly weight setting, can

be set manually or

automatically.

Frequenc-changing

value.When the

batching weight

reaches the

frequency-changin

g value, it will

change to

slow-feeding.

Frequency for slow-feeding


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Fig. 5.3Alarm window on system header

6. Run chart

Click on Run Chart button to display the Run Chart page, see Fig.6.1.

Fig. 6.1Run Chart buttons

6.1 Run Chart of weighing instrument

As shown in Fig.6.1.1, the run chart record the weight changing in the weighing instrument,

and performance indexes such as batching precision, batching rate and interference can

be analyzed according to the run chart.

Fig. 6.1.1 Run chart of weight on weighing instrument

Items in the red solid light frame are the run chart controls. See Fig. 6.1.2.

Alarm

information

Confirm alarm and clear

alarm

Run chart of weighing

instrument


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Fig. 6.1.2 Run chart controls

7. Reports

Click on the “Report” button,see Fig.7.1.

Fig.7.1“Report” button

7.1 Formula Report(detail)

Formula Report (detail) is the report about the batching data of a feed formula (recipe).

Click on the button as shown in Fig.7.1.1, and a dialog box pop up (see Fig.7.1.2), select

the production task in the dialog box, and the corresponding production report is displayed

as shown in Fig. 7.1.3.

Fig. 7.1.1 Formula Report button

Fig. 7.1.2Production Task dialog box

Click to load previous page to

view the history data after

stopping update

Editable Time

range

selection

Stop

update

Print Data statistics


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Fig. 7.1.3 Formula report

7.2Formula Report(total)

Formula Report (total) is the report about production data of a specific feed formula within

a certain period of time.


Formula and Time Range in the dialog box, and the corresponding formula production

report is displayed as shown in Fig. 7.3.3.

Fig. 7.2.1 Button of Formula Report (total)


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Fig. 7.2.2Query range dialog box

Fig. 7.2.3 Formula Production Report


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7.3Material Consumption Report

Material Consumption Report is the report about consumption data of all raw materials.


Time Range in the dialog box, and the corresponding material consumption report is

displayed as shown in Fig. 7.3.3. At the same time, generate the corresponding excel

form under the "Extras" folder under the project folder.

Fig. 7.3.1 Button of Material Consumption Report



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Fig. 7.3.3 Material Consumption Report

7.4Batching Production Report

Batching Production Report is the report about batching data of all tasks within a certain

period of time.


Time Range in the dialog box, and the corresponding batching production report is

displayed as shown in Fig. 7.4.3. At the same time, generate the corresponding excel

form under the "Extras" folder under the project folder.

Fig. 7.3.1 Button of Batching Production Report


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Fig. 7.4.3 Material Consumption Report


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Backup of production data is automatically created when statistics. And the database files

can be called by external system or be used as backup.

Data backup address is D:\YNHF_WCC\Export.

See Fig. 2. Click on the button “Print”, the corresponding reports can be printed out. If

clicking on the button “Delete Statistics”, all production data will be deleted.

Fig. 7.2 Button of Print and Delete Statistics


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8. Control of hammermill

8.1 Control interface

See Fig. 8.1Hammer mill screen. Click the green solid line box, and the PDI control

dialog box pop out. See Fig.8.2.

Fig. 8.1Hammer mill screen

Fig. 8.2 PID control screenfor hammer mill

SP：Set current

PV：Actual current

MV：Set frequency

Run chart of current

PDI control of

hammer mill

SP: Set current

PV: Actual current

MV: Set frequency

Set frequency upper limit

and lower limit

according to the

performance of the

hammermill. When

under Auto PID Control

mode, the frequency is

changed within the limit

range.

PID Control can be operated

automatically or manually. Under

manual mode, the frequency can be

input into the MV box.

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