The Challenge:
Develop a reliable industrial washing machine assembly line automatic control system, which can easily realize supervision and real-time alarm monitoring.
The SoluTIon:
Use NI's CompactRIO hardware and LabVIEW software to build an advanced real-time control and monitoring system, and make the system fully automatic, easy to use and highly reliable. A manufacturer of auto parts needs a real-time control and monitoring system on the line of its industrial cleaning machine, designed to remove grease and some impurities attached to auto parts on the production line. In the manufacturing process of parts, it is necessary to clean every part of its parts and even the smallest details before it can enter the next stage of the production line. The proposed solution needs to be able to display reliable real-time data to the operator and provide an interface to communicate with the user via a touch screen computer.
"By using NI technology, we have developed an advanced, fully-automatic industrial washing machine line, and it is easy to use and maintain. The combination of the CompactRIO platform and LabVIEW helps us solve complex problems quickly, which is better than the market we use. The other products on the list are easier. "
In the industrial industry, there are a series of programmable logic controllers (PLCs) with different performances. However, after comprehensive research on existing products, we chose CompactRIO and NI C series modules as our system development platform. This configuration provides a flexible, high-performance and low-cost solution, and has the same or more superior functions than PLC.
The research team chose the rugged NI cRIO-9074 integrated controller, which combines a 400 MHz industrial real-time processor and a reconfigurable field programmable gate array (FPGA) in a backplane, suitable for embedded Machine control and monitoring applications. From a variety of I / O modules, we chose the NI 9425 drain digital input module to detect the photoelectric signal, the position of the pulse generator and the limit switch. The NI 9476 source digital output module controls pneumatic valves, pneumatic cylinders, water and vacuum pumps, and ensures the precise movement of the load. The NI 9203 data acquisition module measures the vacuum pressure inside the cleaning chamber, while the NI 9211 thermocouple input module measures water, air dryness, load, and chamber temperature.
In addition, the NI PPC-2115 industrial tablet has a built-in touch screen, which has proven to be the right choice for handling communication between the machine and the user. Using industrial tablet computer technology, we provide a user-friendly, highly controllable environment for displaying the status of the entire washer line. This solution saves space and is ideal for large-scale applications with large human-machine interfaces.
In order to control the system, we chose the graphical system design software LabVIEW because it is easy to use, portable, and extensible. And the LabVIEW programming environment also helps to significantly reduce development time.
Implementation of washing machine assembly lineThe cleaning machine assembly line was designed and developed by Bosio doo, mainly based on the needs of two aspects. The first is the transmission system, which ensures the best use of line space by managing the movement of the loaded basket to the last free area of ​​the transmission system. The operator can load the basket and activate the conveyor belt at two locations in the chamber of the washing machine. Before the basket is transported into the washing machine, the system adds a lid to the basket and removes it automatically at the end of the process. In addition, the automatic unloading of the basket is done in two steps.
When developing transmission systems, the main challenge is to ensure speed and reliability. The system uses laser photocells with millimeter accuracy to determine the position of the basket and the next steps. The operation of the basket cover during input / output also requires high precision. We determine the unloading speed of the system by measuring its position using a pulse encoder. The processor detects pulses from the pulse encoder and converts them into suitable units through mathematical calculations. As a result, the correct location of the unloading part is provided.
The second factor is the cleaning process. It includes different stages of the washing cycle, and the process must ensure that the load is clean and dry. The washing process requires proper configuration, which includes a complex combination of mechanical, electrical and programming requirements. Mechanical requirements include many different cleaning options to ensure washing quality. The system can clean the load by combining water jet, load circulation, bubbling with compressed air, vacuuming and heating. At this time, the system acquires and processes a large amount of data. Temperature, pressure, water level, and the position of the basket need to be controlled. A proportional integral derivative (PID) controller that provides accuracy and fast response time completes this task, ensuring consistent cleaning quality.
Using LabVIEW and NI's PPC-2115 industrial tablet, the operator can quickly check the status of the data, including load errors, inactivity, location, and number. Users can monitor the state of the motor, water pump, temperature and pressure. In addition, because LabVIEW is simple and easy to use, the operator can easily write, rearrange, save, load, or use the virtual keyboard to draw the flow chart of the washing machine. Since the system continuously monitors the alarm situation, the error detection time has been greatly reduced.
in conclusionUsually, complex machines designed by engineers need to be used every day by operators who do not have a high level of programming knowledge. These complex systems must precisely manage all necessary operations, but they must provide a clear and user-friendly interface so that technicians can easily operate and use them without the involvement of senior engineers.
The solution we adopt is to provide users with a complex system with high performance by using NI products. It has a simple operation and friendly user interface for communication, with complex functional characteristics and accurate data analysis capabilities. Using NI technology, we have developed an advanced, fully automated industrial washer line that is easy to use and maintain. Combining the capabilities of the CompactRIO platform and LabVIEW helped us quickly solve complex problems, which is easier than using other products on the market.
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