1 Introduction
Beer production process is divided into malt production, wort production, pre-fermentation, post-fermentation, filter sterilization, packaging and other several processes. Beer filling and capping machines are part of the packaging process. After the beer is filtered through the membrane, it is sent to the rotating jar through the pipe, and then enters the bottle through the wine valve. After the bottle is capped, it is bottled beer. The productivity and automation of beer filling and capping machines directly affect the daily production of beer.
In order to meet the increasing demand of the beer industry in China and the requirements for high-speed filling of modern beer filling machinery, domestic beer manufacturers are actively seeking or renovating their beer filling production equipment to make it a good use. Performance, advanced technology, and modern beer filling machines with high production efficiency, reliable operation, and low maintenance costs.
2, beer filling, capping machine working principle and control part
Liquid filling machines can be classified into normal pressure filling machines, pressure filling machines and vacuum filling machines according to the filling principle. Beer filling and capping machines use pressure filling methods, which are performed at a pressure higher than atmospheric pressure. The pressure in the reservoir is higher than the pressure in the bottle, and the beer liquid flows into the bottle by pressure differential.
The current domestic and international realization of the filling process route is basically: using the rotary motion generated by the rotary jar, the empty bottle placed on the wine jar slot is opened by the mechanical mechanism to the vacuum valve fixed on the upper part of the wine jar. The sealed bottle is vacuumed, dialed to open the valve stem, opened the gas valve, and filled the bottle with CO2 gas. The vacuum cam continues to open the vacuum valve. The bottled air and CO2 gas mixture are extracted and the gas valve is opened again. The bottle is filled with CO2 gas, and the liquid valve in the filling valve is opened when the pressure in the bottle approaches the pressure of the back pressure gas. The liquor is poured into the bottle along the bottle wall, and the filling of the beer is accomplished through pneumatically or electrically controlled filling valves.
Today's international advanced beer filling and capping machine control system is mainly composed of photoelectric switch position detection part, bottle conveyor belt, wine jar speed frequency control part, main control consists of programmable controller, touch screen and other components. The mechanical structure of the filling and capping machine is integrated with modern automatic control technology such as PLC programmable control, variable frequency stepless speed regulation, and man-machine interface, to form a mechanical and electrical integration.
3, control part of the renovation program
The automation level of control systems for filling and capping machines currently used by many domestic beer manufacturers is uneven; all manual buttons and process switches are located on the front panel of an operation box. Most of the PLC controllers are OMRON or Mitsubishi. The early products, equipment chain control, and protection settings are small. In addition, the on-site environment of the beer filling is severe and the humidity is high, which causes serious rust on the contact points of the switches, etc., and the failure rate of the signal detection part of the system is high, resulting in the operation of the equipment control system. Low reliability, short equipment operation cycle, etc.
Taking the control system of the filling and capping machine of the actually transformed Dandong Yalujiang Beer Co., Ltd. as an example, the transformation method was introduced, and the control ideas and ideas for remoulding such equipment were clarified; the operation of the PLC was rewritten according to the actual process conditions at the site. program. According to the actual conditions of the beer filling and capping machine control system, and according to the actual process conditions of the site, the PLC control system of the equipment was redesigned. This transformation method and idea can also be applied to the transformation of other liquid medium filling equipment.
3.1 System Hardware Configuration
Mitsubishi's FX2N128MRPLC is used to replace the 2 OMRON's C60PPLC used in the original system. Because the original system's PLC is an old model product, a special communication converter needs to be configured when connecting to a computer. When the system needs to add an external I/O input point, Expansion module spare parts are hard to find. The FX2N128MRPLC is a 128-point I/O-integrated box controller with the advantages of fast operation speed, rich instruction, high performance-to-price ratio, simple on-line programming, and easy expansion. It is the most powerful small controller in the Mitsubishi FX series.
(1) Mitsubishi's 900 Series 970GOT man-machine touch panel is used to replace the panel buttons used in the original system and monitor the operating parameters of the display device. The 970GOTHMI is a high-brightness 16-color display that is connected directly to the FX2N128MRPLC's CPU via a bus connection for fast response. There are many maintenance functions, such as list editing function, ladder diagram monitoring (fault-finding) function, system monitoring function, etc., to troubleshoot and maintain the PLC system.
(2) The inverters of filling and capping machines were not replaced during the transformation. The means of on-site detection of signals still used switch-type detection. Because the detection switches were used for occasions with high humidity, the capacitive proximity switches were selected. PLCI/O terminal connection mode, select the PNP type proximity switch.
3.2 System Programming
The key point of program design of the PLC controller is centered on the rotation speed control of the wine jar and detection displacement of the relevant position of the 60 bottles on the wine jar, the detection displacement of the broken bottle, the relevant position of the empty bottle position, and related filling. Valves and other controls. In the bottle displacement detection program, the Mitsubishi PLC left shift instruction was used. When the drive execution condition input changes from OFF to ON each time, N2 bit movement is performed, and N2 is the number of shifts.
(1) Bottle Displacement Subroutine
413LDX055; Machine Count Pulse Measurement Detection Input Point
414PLSM49; Main motor speed measurement detection input point after rising differential D49
416PLFM301; The main motor speed measurement detection input point to take the differential edge after the bit M301
418LDIM590; number of bottles into the detection
419ANIX005; Chain Protection Point
420ANIX006; Emergency Parking Protection
421OUTM50; Bottle inspection
422LDM49; main motor speed measurement detection input point
423SFTLM50M500K60K1
Bottle displacement detection
The use of PLC left shift instruction, this instruction is one of the core of the entire sub-control program, the main motor and the bottle position detection switch synchronously detects the moving wine bottle, the main motor rotates one bottle for each rotation of the wine bottle. The unit corresponding to the 60 bottles in the internal unit of the PLC is M500~M559. The number of units is set to K60 by the first letter K. Each change is set to K1 by the second letter K. The M50 reflects the bottle position. The position of the empty and missing, and this detected position is shifted to the frequency of the motor speed, the corresponding unit is built in the internal "1" or "0", control the opening and closing of the corresponding valve and the motor of the mixing cap . After the system continuously detects 90 empty bottles, the operation of the motor that stirs the caps is stopped. The number of bottles to be tested can be arbitrarily set according to the user's requirements.
432LDX052
Bottle detection
The rotating kiln tank presses the bottle back into the bottle during the filling process. After the empty bottle is back pressure, the bottle may suddenly burst due to cracks on the bottle itself. This requires the detection of the location of the decanter bottle. The position is performed by opening the purge solenoid valve, ejecting the compressed air, blowing the smashed bottle pieces on the bottle position away from the position, after continuously purging several bottle positions, after opening the injection solenoid valve, jetting out the high pressure water jet, in the pair Several bottles are sprayed consecutively around the bottle position.
(2) Achieve bottleneck detection and control step control
482LDX055; Machine Count Pulse Measurement Detection Input Point
483PLSM49; Main motor speed measurement detection input point after rising differential D49
485PLFM309; The main motor speed measurement detection input point to take the differential point after the falling edge M309
486LDIM70; Broken Bottle Location Detection
487ANIM071; Continuous broken bottle position detection
488ANIX052; into the bottle position
489SFTLM52M600K20K1
The broken bottle detection and the bottle position detection switch synchronously detect the moving broken bottle, and the main motor rotates one bottle position for each revolution of the main motor. The unit corresponding to the 20 broken bottle positions in the PLC internal unit is M600~M619. The number is set to K20 with the first letter K. Each change is set to K1 with the second letter K. M52 reflects the position of the broken bottle and shifts this detected position to the frequency of the motor speed. The corresponding internal unit is built with "1" or "0" to control the opening and closing of the corresponding injection and purge solenoid valves. The opening and stopping time of continuous injection and purge solenoid valves can be arbitrarily set according to process requirements.
The reliable guarantee of system automation running is to control the synchronous tracking of the in and out caps, and accurately detect the three conditions of the motor rotation speed detection switch, the bottle breaking detection switch and the bottle entering detection switch.
(3) The software of the 970GOT man-machine touch screen operation terminal adopts Mitsubishi's GTWORKS software package, of which GTDesigner is a drawing suit software used with the entire GOT9000 series. The software package is simple to operate, can be configured and simulated on a personal computer in advance, and then downloaded to a human-machine operation terminal. At the same time, because the human-machine interface has the function of a touch screen, the commonly used switches are set on the display screen to facilitate the operation. Can also add some functions, such as setting alarm information.
4, after the transformation of the control system function
When the system is in normal operation, the machine is controlled automatically. According to the shortage of the bottles brought in and out of the bottle, it is run at a set speed or at a slow speed. The bottle is inserted into the bottle, no bottle is not covered, the bottle is automatically washed, and the filling position is automatically back pressured. , The coordination and interlocking of the actions such as the automatic opening and stopping and safety protection of the under cover feeding system. The original operation of all buttons was changed on the touch screen.
5, the monitoring function of the control system detection status
The incoming bottle detection switch and the bottle breaking detection switch detect the positions of the small iron pieces above each pressure bottle part to generate the photoelectric pulse output, and then the PLC collects, because the position of the small iron pieces above each pressure bottle part is active. After the machine has been running for a period of time, the position of the small iron piece and the detection switch above the pressure bottle part is displaced, causing the detection switch to misjudge, if the bottle is judged to be a bottle, the bottle explosion detection, misdetection, etc. cause output errors. Causes the PLC to malfunction, causing malfunctions such as back pressure, burst bottle blowing, washing, and bottle cap mixing system failure.
In the daily production process before the transformation, when this phenomenon is encountered, the operator can only switch each function switch or button to a manual control position, so that the machine and equipment work in an unsupervised state and the machine loses the automatic control function. Caused a great waste of raw materials such as gas, water, and wine. Only in the production interval can the gap between the detection switch and the small iron be corrected by the maintenance fitter and the electrician adjusting the installation position of the detection switch with a displacement distance of only 5 to 8 mm according to the detection and switching of the small LED on the switch. . This kind of detection method is very backward. After adjusting the effect, it cannot respond to the adjustment result in time.
For this detection situation, combined with the configuration of the filling and capping machine control system after modification, this part of the detection function was added and integrated in the human-machine touch screen to complete the bottle position detection.
On the interface screen of human-machine touch screen, it can dynamically display the state of 60 bottles and the state of the bottles at the time of bottle explosion. There are bottle, bottle, bottle, back pressure switch and other detection switches, stirring motor, etc. The on-off state of the solenoid valve is displayed in different colors, which is very intuitive.
When it is necessary to rectify the position of the detection switch and the small iron piece, under the normal production conditions, the machine can be stopped without any maintenance. As long as the maintenance personnel can adjust the bottle status according to the status of the bottle on the display screen, the adjustment effect can be seen immediately. . In routine maintenance, it can also be used as a condition monitoring device to observe the operating status of the output device.
The addition of this system function is specifically designed to ensure the normal operation of the automatic control system of the irrigation capping machine.
6. Concluding remarks
The remodeled control system greatly simplifies the complex mechanical structure. After the on-site operating conditions and control effects have been verified, the degree of automation of the system has met the design requirements, greatly reducing the labor intensity of the operators, and making the daily output of beer-like irrigation faster than in the past. Increased by more than 30%, the failure rate is greatly reduced. Embodies the automatic control technology of modern equipment. It is the most advanced filling control system in the country, which is based on the digestion and absorption of advanced technology controlled by today's industry.
Beer production process is divided into malt production, wort production, pre-fermentation, post-fermentation, filter sterilization, packaging and other several processes. Beer filling and capping machines are part of the packaging process. After the beer is filtered through the membrane, it is sent to the rotating jar through the pipe, and then enters the bottle through the wine valve. After the bottle is capped, it is bottled beer. The productivity and automation of beer filling and capping machines directly affect the daily production of beer.
In order to meet the increasing demand of the beer industry in China and the requirements for high-speed filling of modern beer filling machinery, domestic beer manufacturers are actively seeking or renovating their beer filling production equipment to make it a good use. Performance, advanced technology, and modern beer filling machines with high production efficiency, reliable operation, and low maintenance costs.
2, beer filling, capping machine working principle and control part
Liquid filling machines can be classified into normal pressure filling machines, pressure filling machines and vacuum filling machines according to the filling principle. Beer filling and capping machines use pressure filling methods, which are performed at a pressure higher than atmospheric pressure. The pressure in the reservoir is higher than the pressure in the bottle, and the beer liquid flows into the bottle by pressure differential.
The current domestic and international realization of the filling process route is basically: using the rotary motion generated by the rotary jar, the empty bottle placed on the wine jar slot is opened by the mechanical mechanism to the vacuum valve fixed on the upper part of the wine jar. The sealed bottle is vacuumed, dialed to open the valve stem, opened the gas valve, and filled the bottle with CO2 gas. The vacuum cam continues to open the vacuum valve. The bottled air and CO2 gas mixture are extracted and the gas valve is opened again. The bottle is filled with CO2 gas, and the liquid valve in the filling valve is opened when the pressure in the bottle approaches the pressure of the back pressure gas. The liquor is poured into the bottle along the bottle wall, and the filling of the beer is accomplished through pneumatically or electrically controlled filling valves.
Today's international advanced beer filling and capping machine control system is mainly composed of photoelectric switch position detection part, bottle conveyor belt, wine jar speed frequency control part, main control consists of programmable controller, touch screen and other components. The mechanical structure of the filling and capping machine is integrated with modern automatic control technology such as PLC programmable control, variable frequency stepless speed regulation, and man-machine interface, to form a mechanical and electrical integration.
3, control part of the renovation program
The automation level of control systems for filling and capping machines currently used by many domestic beer manufacturers is uneven; all manual buttons and process switches are located on the front panel of an operation box. Most of the PLC controllers are OMRON or Mitsubishi. The early products, equipment chain control, and protection settings are small. In addition, the on-site environment of the beer filling is severe and the humidity is high, which causes serious rust on the contact points of the switches, etc., and the failure rate of the signal detection part of the system is high, resulting in the operation of the equipment control system. Low reliability, short equipment operation cycle, etc.
Taking the control system of the filling and capping machine of the actually transformed Dandong Yalujiang Beer Co., Ltd. as an example, the transformation method was introduced, and the control ideas and ideas for remoulding such equipment were clarified; the operation of the PLC was rewritten according to the actual process conditions at the site. program. According to the actual conditions of the beer filling and capping machine control system, and according to the actual process conditions of the site, the PLC control system of the equipment was redesigned. This transformation method and idea can also be applied to the transformation of other liquid medium filling equipment.
3.1 System Hardware Configuration
Mitsubishi's FX2N128MRPLC is used to replace the 2 OMRON's C60PPLC used in the original system. Because the original system's PLC is an old model product, a special communication converter needs to be configured when connecting to a computer. When the system needs to add an external I/O input point, Expansion module spare parts are hard to find. The FX2N128MRPLC is a 128-point I/O-integrated box controller with the advantages of fast operation speed, rich instruction, high performance-to-price ratio, simple on-line programming, and easy expansion. It is the most powerful small controller in the Mitsubishi FX series.
(1) Mitsubishi's 900 Series 970GOT man-machine touch panel is used to replace the panel buttons used in the original system and monitor the operating parameters of the display device. The 970GOTHMI is a high-brightness 16-color display that is connected directly to the FX2N128MRPLC's CPU via a bus connection for fast response. There are many maintenance functions, such as list editing function, ladder diagram monitoring (fault-finding) function, system monitoring function, etc., to troubleshoot and maintain the PLC system.
(2) The inverters of filling and capping machines were not replaced during the transformation. The means of on-site detection of signals still used switch-type detection. Because the detection switches were used for occasions with high humidity, the capacitive proximity switches were selected. PLCI/O terminal connection mode, select the PNP type proximity switch.
3.2 System Programming
The key point of program design of the PLC controller is centered on the rotation speed control of the wine jar and detection displacement of the relevant position of the 60 bottles on the wine jar, the detection displacement of the broken bottle, the relevant position of the empty bottle position, and related filling. Valves and other controls. In the bottle displacement detection program, the Mitsubishi PLC left shift instruction was used. When the drive execution condition input changes from OFF to ON each time, N2 bit movement is performed, and N2 is the number of shifts.
(1) Bottle Displacement Subroutine
413LDX055; Machine Count Pulse Measurement Detection Input Point
414PLSM49; Main motor speed measurement detection input point after rising differential D49
416PLFM301; The main motor speed measurement detection input point to take the differential edge after the bit M301
418LDIM590; number of bottles into the detection
419ANIX005; Chain Protection Point
420ANIX006; Emergency Parking Protection
421OUTM50; Bottle inspection
422LDM49; main motor speed measurement detection input point
423SFTLM50M500K60K1
Bottle displacement detection
The use of PLC left shift instruction, this instruction is one of the core of the entire sub-control program, the main motor and the bottle position detection switch synchronously detects the moving wine bottle, the main motor rotates one bottle for each rotation of the wine bottle. The unit corresponding to the 60 bottles in the internal unit of the PLC is M500~M559. The number of units is set to K60 by the first letter K. Each change is set to K1 by the second letter K. The M50 reflects the bottle position. The position of the empty and missing, and this detected position is shifted to the frequency of the motor speed, the corresponding unit is built in the internal "1" or "0", control the opening and closing of the corresponding valve and the motor of the mixing cap . After the system continuously detects 90 empty bottles, the operation of the motor that stirs the caps is stopped. The number of bottles to be tested can be arbitrarily set according to the user's requirements.
432LDX052
Bottle detection
The rotating kiln tank presses the bottle back into the bottle during the filling process. After the empty bottle is back pressure, the bottle may suddenly burst due to cracks on the bottle itself. This requires the detection of the location of the decanter bottle. The position is performed by opening the purge solenoid valve, ejecting the compressed air, blowing the smashed bottle pieces on the bottle position away from the position, after continuously purging several bottle positions, after opening the injection solenoid valve, jetting out the high pressure water jet, in the pair Several bottles are sprayed consecutively around the bottle position.
(2) Achieve bottleneck detection and control step control
482LDX055; Machine Count Pulse Measurement Detection Input Point
483PLSM49; Main motor speed measurement detection input point after rising differential D49
485PLFM309; The main motor speed measurement detection input point to take the differential point after the falling edge M309
486LDIM70; Broken Bottle Location Detection
487ANIM071; Continuous broken bottle position detection
488ANIX052; into the bottle position
489SFTLM52M600K20K1
The broken bottle detection and the bottle position detection switch synchronously detect the moving broken bottle, and the main motor rotates one bottle position for each revolution of the main motor. The unit corresponding to the 20 broken bottle positions in the PLC internal unit is M600~M619. The number is set to K20 with the first letter K. Each change is set to K1 with the second letter K. M52 reflects the position of the broken bottle and shifts this detected position to the frequency of the motor speed. The corresponding internal unit is built with "1" or "0" to control the opening and closing of the corresponding injection and purge solenoid valves. The opening and stopping time of continuous injection and purge solenoid valves can be arbitrarily set according to process requirements.
The reliable guarantee of system automation running is to control the synchronous tracking of the in and out caps, and accurately detect the three conditions of the motor rotation speed detection switch, the bottle breaking detection switch and the bottle entering detection switch.
(3) The software of the 970GOT man-machine touch screen operation terminal adopts Mitsubishi's GTWORKS software package, of which GTDesigner is a drawing suit software used with the entire GOT9000 series. The software package is simple to operate, can be configured and simulated on a personal computer in advance, and then downloaded to a human-machine operation terminal. At the same time, because the human-machine interface has the function of a touch screen, the commonly used switches are set on the display screen to facilitate the operation. Can also add some functions, such as setting alarm information.
4, after the transformation of the control system function
When the system is in normal operation, the machine is controlled automatically. According to the shortage of the bottles brought in and out of the bottle, it is run at a set speed or at a slow speed. The bottle is inserted into the bottle, no bottle is not covered, the bottle is automatically washed, and the filling position is automatically back pressured. , The coordination and interlocking of the actions such as the automatic opening and stopping and safety protection of the under cover feeding system. The original operation of all buttons was changed on the touch screen.
5, the monitoring function of the control system detection status
The incoming bottle detection switch and the bottle breaking detection switch detect the positions of the small iron pieces above each pressure bottle part to generate the photoelectric pulse output, and then the PLC collects, because the position of the small iron pieces above each pressure bottle part is active. After the machine has been running for a period of time, the position of the small iron piece and the detection switch above the pressure bottle part is displaced, causing the detection switch to misjudge, if the bottle is judged to be a bottle, the bottle explosion detection, misdetection, etc. cause output errors. Causes the PLC to malfunction, causing malfunctions such as back pressure, burst bottle blowing, washing, and bottle cap mixing system failure.
In the daily production process before the transformation, when this phenomenon is encountered, the operator can only switch each function switch or button to a manual control position, so that the machine and equipment work in an unsupervised state and the machine loses the automatic control function. Caused a great waste of raw materials such as gas, water, and wine. Only in the production interval can the gap between the detection switch and the small iron be corrected by the maintenance fitter and the electrician adjusting the installation position of the detection switch with a displacement distance of only 5 to 8 mm according to the detection and switching of the small LED on the switch. . This kind of detection method is very backward. After adjusting the effect, it cannot respond to the adjustment result in time.
For this detection situation, combined with the configuration of the filling and capping machine control system after modification, this part of the detection function was added and integrated in the human-machine touch screen to complete the bottle position detection.
On the interface screen of human-machine touch screen, it can dynamically display the state of 60 bottles and the state of the bottles at the time of bottle explosion. There are bottle, bottle, bottle, back pressure switch and other detection switches, stirring motor, etc. The on-off state of the solenoid valve is displayed in different colors, which is very intuitive.
When it is necessary to rectify the position of the detection switch and the small iron piece, under the normal production conditions, the machine can be stopped without any maintenance. As long as the maintenance personnel can adjust the bottle status according to the status of the bottle on the display screen, the adjustment effect can be seen immediately. . In routine maintenance, it can also be used as a condition monitoring device to observe the operating status of the output device.
The addition of this system function is specifically designed to ensure the normal operation of the automatic control system of the irrigation capping machine.
6. Concluding remarks
The remodeled control system greatly simplifies the complex mechanical structure. After the on-site operating conditions and control effects have been verified, the degree of automation of the system has met the design requirements, greatly reducing the labor intensity of the operators, and making the daily output of beer-like irrigation faster than in the past. Increased by more than 30%, the failure rate is greatly reduced. Embodies the automatic control technology of modern equipment. It is the most advanced filling control system in the country, which is based on the digestion and absorption of advanced technology controlled by today's industry.