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7/24/2019 Compact Workstation 2005 En
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Process Control Systems
The new training system for process control
Process Control Compact Workstation
All in a state of flux...Measuring, controlling, regulating
with PLC, PC or controllers of your choice!
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Process technology is not only
simple like basic principles of a water
treatment process or production of
food. It can be as highly complex as a
technical processes.No matter the complexity of process
technology to learn about the fundamentals
of open and closed-loop control technology
is always the first step.
This is why Process Control System
is an important part of our
Learning System for Automation.
The concept
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To assemble, tube and pipe up, wire and
commission pneumatic process drives.
To understand the concepts of process
engineering, such as shutting off, opening,
closing and regulating . . . To be able to read and create flow diagrams and
documentation.
To operate and monitor processes via PC.
To learn about fieldbus technology and how toparameterise a fieldbus, e.g. PROFIBUS.
To learn about and work on overall processes.
To design, tube up, wire, commission,
test, maintain and repair process
engineering systems.
To measure, control and regulate
electrical and process engineering
variables such as temperature, flow,
pressure and level.
To analyse control systems,
parameterise and optimise closed-loop
control systems.
To develop, adapt and parameterise
PLC programs.
Important objectives
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Does getting into the subject of closed-loop
control really require an extensive knowledge
of mathematics?
We say NO !
We believe that practice-orientedqualification is: Learning by doing
and understanding the effective
interrelationships within a control loop.
With the knowledge gained from the process,
you are able to conclude formulas or
calculation methods.
The system can be used for open and closed-
loop control!
Multfaceted learning situation
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In order to get the maximum benefit from your investment, we recommend that you use
the system right from start of vocational training. The system can be used e.g. to start with
electrical control technology and later for the fundamentals of programmable logic
controllers. Binary input and output signals can be used for this purpose .
A simple control task could for instance be as follows:
After the start button has been pressed, the pump is started and water pumped into the
upper container. The pump is switched off once the float switch is activated. Than the
return line into the lower container is opened by reversing the pneumatic process
actuator. The pneumatic process actuator closes if a signal is generated by the upper float
switch.
Control technology
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The binary 24 V signal is wired to the
I/O terminal (SysLink interface in the
form of an input
However, it could also be used as a
safety limit switch to switch off thepump by means of a relay circuit
The switching solenoid is located
in a transparent float housing, where
it is easily visible.
Float switch in the container lid
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Depending on assembly position, thefloat switch can be used either to switch
the increasing or decreasing
water level.
The binary 24 V signal is wired to theI/O terminal in the form of an input.
However, it could also be used in the
form of a safety signal to switch off the
pump via relay circuit.
The connecting cables are fitted with a
plug/socket to facilitate conversion
with a minimum of wiring complexity.
Float switch housing for lateral installation
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Two capacitive sensors at the rear of the
lower container may be used to
monitor the level of the water.
The sensor can be mechanically
adjusted on an aluminum profile.
One important objective is setting the
sensor correctly so that it detects the water
level through the container wall.
The binary 24 V signal is wired to
the I/O terminal in the form of an input.
Capacitive level sensors see through the container wall
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A centrifugal pump with an output of approx.10 l/min ensures continuous flow of water.
The voltage can be varied by means of the
motor controller and as such the speed of the
pump.
Input 0-10 VDC, Output 0-24 VDC.
Furthermore, the pump motor could also be
switched on or off by means of a relay
circuit via digital signal.
One system two analog manipulated variables 1#2
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The directly actuated proportional 2/2-way valveenables the flow control of fluids.
It is suitable as a remotely adjustable control
element for open and closed-loop control.
The valve piston is lifted steplessly from its seat
as a function of the solenoid coil current.
An external standard signal is converted into a
PWM signal and the opening of the valve is
therefore infinitely adjustable. The frequency can
be harmonised between the PWM signal and the
valve in use.
Standard signals 0-10VDC, 0-20mA,4-20mA
One system two analogue variables 2#2
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This compact system combines 4 controlledsystems, which can be operated individually or
in cascaded form, depending on the technical
requirements.
Examples of closed-loop control functions:
2-point control for filling level
PI controller for the pressure
controlled system
I-controller for filling level PID controller for flow rate
Closed-loop control technology
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The pump delivers a fluid from a storagecontainer into the above situated
reservoir. The level in the reservoir is
detected by means of an analog ultrasonic
sensor.
The controlled filling level system can be
used as an I or PT1 controlled system.
Acoustic sensor 4-20 mA
Controlled level system
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The pump delivers a fluid from thereservoir via a piping system.
The flow rate is detected by means of an
optoelectronic vane sensor in the form of
an actual value.
The system used is a controlled system
with self-regulation (P-controlled
system); it does not have a time delay.
The control loop in combination with the
pump (PT1 behavior) creates an easilycontrollable system.
Flow sensor with frequency signal
Controlled flow system
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Via a piping system, the pump delivers a fluidfrom a reservoir into a gas-prefilled pressure
tank. The pressure of the gas (air) in the
pressure tank is detected by means of a
piezoresistive relative pressure sensor in the
form of an actual value.
Two variations of manipulated variables:
1. Pressure control via the pump speed
2. Pressure control via the proportional
directional control valve
Pressure sensor 0-10 V
Pressure control
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The water in the reactor vessel of the heatexchanger is heated by means of a heating element
is recirculated by means of the pump.
A PT100 sensor is used for temperature sensing.
The on/off switching period of the heating element,which is the manipulated variable, determines the
heat output of the heat exchanger.
The switching voltage is 24 VDC and the supply
voltage 230 VAC.
Heater, 1000 W insulated with PT 100temperature sensor
Controlled temperature system
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Meaning and application areas forpneumatic process actuators
Sizing, configuration and adjustment of
rotary actuators used as valve actuators
viewed from the perspective of a worst-case
scenario
Analysis of media flow, gas, fluids, bulk
material
Standards for valve actuators, ISO 5211,
DIN3337, VDI/VDE 3845 Namur
Explosion protection, basic terminology,
definition of hazardous zones
Rotary actuator SYPAR, Namur valve,ball valve, electrical signal box and
water as process medium
Pneumatics in conjunction with extrusion processes
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PLC control,
e.g. Siemens S7
Commissioning/testing
using the Festo simulation
box
PC activation using Festo
EasyPort, digital/analog
Industrial controller,Siemens Sipart DR9
I/O SysLink terminal block
like Festo MPS
Electrical interfaces for customized control
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Syslink I/O module
Analog 15pin Sub-D terminal block
Top-hat rail relay
Measuring transformers
Motor controller 0-10V > 0-24 V for
the pump motor
Mechanical adaptation via
ER-frame clips
Wiring board with measuring transducer
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This frame is adjustable so that both levels
can be equipped with ER-units.
Easy to reassemble from DIN A4 to ER.
The wiring board is easy to remove
and conveniently accessible.
Cabinet frame for DIN A4 and ER units
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Size wxdxh 700 x 700 x 935 mmD + approx. 100 mm for the PLC towards
the rear
Weight approx. 45 kg
Voltage supply 24 VDC, 2 A
Compressed air supply approx. 6 bar
General technical data
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Your contact persons for further
information:
Festo Didactic Solution Center
Nael Abu-Sinni: [email protected]
Phone:+4971134671424
Fax: +49711347541424