BO CO BI TP LN

THIT K H THNG T NG HA
( Cng ngh: my kim tra rnh trn sn phm )
I/ Ni dung

Thit k s nguyn l
Tnh chn mch lc, mch iu khin
Thit k s u dy
M phng s dng phn mm Automation Studio bng 3 phng php:
Lu
Ma trn trng thi
GRAFCET

1. Yu cu cng ngh
H thng trn c dng kim tra rnh ca sn phm ng thi tin hnh doa l ct ba
via. H thng hot ng nh sau: Ban u c 4 xi lanh ang thu v. Khi c vt cn kim
tra c a ln bn trt th cm bin P pht hin c vt. n nt START xi lanh A y
vt ra n v tr g sau thu v. Sau khi xi lanh A thu v th xi lanh D y M i xung.
Khi chm cm bin v tr d1 th xi lanh B y bn ra tin hnh kim tra v qua doa l ln
th nht. Khi y ht hnh trnh th xi lanh B dng. Thi gian y ca xi lanh l 3 giy.
Trong 3 giy m xi lanh B cha y ht hnh trnh hoc xy ra li u doa b kt vo l
th xi lanh t ng thu v v dng li. n nt SA CHA th h thng tip tc hot
ng. Xi lanh B y ht hnh trnh th xi lanh C y. Khi chm cm bin c1 th xi lanh B
thu v doa l ln th hai. Qu trnh thu v cng din ra trong 3 giy. Nu gp s c nh
doa l ln 1 th xi lanh B li y ra v dng li. n nt SA CHA th xi lanh B thu v.
Xi lanh B thu v ht hnh trnh th xi lanh C thu v. Xi lanh D y M i ln. Kt thc 1
chu trnh.

 S nguyn l cng ngh ( Bn v trang sau )

2. Tnh ton chn mch lc v mch iu khin
2.1. Tnh ton chn mch lc
2.1.1. My nn kh
Da vo yu cu cng ngh ca h thng nh khi lng ca bn my, lc y
ca cc xi lanh, kh nng chu ng ti a cho php ca cc van kh nn iu
khinta tin hnh la chn cc loi my nn kh ph hp.
Theo p sut lm vic, my nn kh c phn loi thnh:
My nn kh p sut thp: p 15 Bar
My nn kh p sut cao: p 15 Bar
My nn kh p sut rt cao: p 300 Bar
Theo nguyn l hot ng, my nn kh c phn loi thnh:
My nn kh pittong, cnh gt, trc vt, li tm.
i vi bi tp ln ny em chn loi my nn kh p sut thp p 15 Bar kiu
Pittong.

Hnh 2.1. My nn kh pittong

2.1.2. B chun b ngun kh nn

ngun kh cp cho h thng m bo sch s, chng c bi bn v lc kh

m nh hng n tui th ca cc c cu chp hnh ta s dng b chun b
ngun kh nn bao gm 3 phn t b lc tch m, van iu p v b phun du
bi trn.

Hnh 2.2. B chun b ngun

B lc v tch m: Gip lc cht bn v

ngng t hi nc

Van iu p: gi cho p sut iu chnh

khng i mc cho c s dao ng bt
thng ca p sut u vo hoc c s
thay i ca ti trng p ng

Cung cp du bi trn cho kh nn

dng sng lm cc thit b chp hnh
hot ng trn chu v chng g.

2.1.3. ng ng cp kh nn
Chc nng: truyn ti dng kh nn n ni tiu th.

Hnh 2.3

Hnh 2.4

2.1.4. Xi lanh kp

Hnh 2.5. Xi lanh kp c cm bin tim cn

Trong c cu truyn ng ta s dng thit b chp hnh l xi lanh kh nn
Cc thng s ca xi lanh ta chn theo nh bng sau:
S xi lanh cn chn
Kiu tc ng
Mi cht
Chiu di hnh trnh
ng knh tit din
Cm bin tim cn

4
2 chiu
Kh
Ty thuc cng ngh
Ty thuc cng ngh
2 u mi xi lanh

Tnh ton ng knh tit din xi lanh v chiu di hnh trnh:

Trc ht tnh c tit din xi lanh ta cn quy i n v
1 Bar = 1Kg/cm2
Din tch tit din ca xi lanh c tnh theo cng thc:
M
S
S = P = * R2 => D = 2R = 2*

S
M
P
R
D

: Din tch tit din ca xi lanh ( cm2 )

: Ti trng p ng ( KG )
: p sut kh nn (KGf/cm2)
: Bn knh tit din ca xi lanh ( cm )
: ng knh tit din ca xi lanh ( cm )

 i vi yu cu v thng s ca h thng thc t, p dng cng thc trn ta c

th tnh ton c tit din xi lanh cho ph hp. Do p sut kh nn ch t 95%
nn khi tnh ton ta cn cng thm 10% ti trng p ng tha mn yu cu.
2.1.5. Van iu khin in kh nn 5/2
Xi lanh c iu khin bi van in kh nn 5/2 iu khin hai pha c nh.

Hnh 2.6. Cu to c kh van in kh nn 5/2

Hnh 2.7. Van in kh nn 5/2

Bng thng s k thut ca van la chn

THNG S K THUT VAN 5/2 IN KH NN

Kiu van
Loi van
Vng tc ng hiu qu
p sut lm vic (MPa)
p sut ti a chu c (MPa)
Nhit thch hp (oC)
in p hot ng ca cun dy
Tm hot ng ca in th
Thi gian tc ng

4V220-08
5 ca hai trng thi, c nh
16 mm2
0.15 0.8 MPa
1.2 MPa
-5 - 50
24 VDC
10%
0.05s

p sut my nn kh ta chn trc nh hn 15 Bar nn chn van iu khin

trn l hp l.

2.1.6. Van tit lu 1 chiu cho xi lanh

Hnh 2.8. Van tit lu 1 chiu

2.2. Tnh ton chn mch iu khin

2.2.1. Chn b iu khin PLC
i vi h thng nh trn c tng cng 12 u vo v 14 u ra em la chn
PLC Rockwell Compact Logix L32E iu khin hot ng ca cng ngh.
Cu to ca PLC Compact Logix L32E bao gm 4 phn: khi CPU, khi ngun
cp, khi truyn thng v khi vo ra IO

Hnh 2.9. PLC Rockwell 1769 L32E

Module CPU

Hnh 2.10. Module CPU

Module ngun

Hnh 2.11. Module ngun

Module ngun c tn 1769-PA2 seri A rev 3.
Thng s k thut:

in p vn hnh: 85-265 VAC, 47-63 Hz.

Cng sut tiu th: 110 VA in p 110 VAC v 130VA 240 VAC.
Dng ti a: 2.0A in p 5V, 0.8A 24V.

Module truyn thng

Module ny c tn DeviceNet Scanner 1769-SDN/B seri B rev
Thng s k thut:
-

Tc truyn thng: 125 Kbps vi khong cch ti a 500m, 250 Kbps

khong cch ti a 250m, 500 Kbps vi khong cch ti a 100m.
Dng yu cu ti a: 90 mA in p 110 VDC, 110 mA in p
25VDC.
S node kt ni ti a: 64.

Hnh 2.12. Module truyn thng

Module vo ra

Hnh 2.13. Module vo s

Hnh 2.14. Module ra s

2.2.2. La chn Aptomat ( MCB ) bo v PLC

Theo thng s k thut ca ngun cp cho PLC, Cng sut tiu th ca PLC
240VAC l 130 VA nn ta tnh c dng tiu th khi l xp x 0.8A. Vy
ta s la chn loi Aptomat 1 pha c dng lm vic gp 1.5 ln dng lm vic
ca PLC => ta chn aptomat c dng lm vic 1.2A.
2.2.3. La chn r le trung gian
Ta la chn r le trung gian ng ct cho cc van iu khin da vo cc
thng s sau:
Dng in nh mc ca r le: l dng in ln nht cho php r le lm

vic trong thi gian di m khng b h hng. Khi chn r le trung gian
th dng in nh mc ca n khng c nh hn dng nh mc ca
ph ti ( y l dng nh mc ca van kh nn )
Im = (1.2 1.5 ) Itt
in p cung cp cho cun ht ca r le l mc in p khi r le hot

ng. in p ny phi ph hp vi b iu khin PLC nn in p cun

ht l 24VDC.
Qua em chn r le trung gian OMRON MY4N iu khin h
thng.

Hnh 2.15. Cu to r le trung gian

Cc thng s ca r le MY4N
- in p cun dy: 24 VDC c LED hin th
- Thng s tip im: dng chu c ti a 5A 28 VDC
dng chu c ti a 5A 250 VAC

Hnh 2.16. S u dy trong r le trung gian

2.2.4. La chn cm bin quang
La chn in p cp cho cm bin phi ph hp vi in p ca mch iu
khin. Do mch iu khin kt ni vi PLC nn in p ca cm bin l
24VDC.

Hnh 2.17. Cm bin quang

Hnh 2.18. S u dy cm bin quang

Cc thng s ca cm bin quang c la chn

Khong cch pht hin c vt: 0 30 cm
Loi u ra NPN thng h, 3 dy ( xanh, nu, en )
in p hot ng 6 36 VDC
Dng in u ra 300mA
Mi trng lm vic: -40oC 70oC
Chiu di dy: 1m
Pht hin cc i tng: m c.

2.2.5. Nt n, cng tc

Hnh 2.19. Nt n
Cc thng s ca nt n
Dng in nh mc 5A
in p nh mc 400V
Tui th rt cao.

2.2.6. n bo

Hnh 2.20. n bo
La chn loi n bo AD16-22DS vi cc thng s k thut:
in p cp 24VDC, 24VAC
Dng in < 20 mA
2.2.7. Tnh ton la chn dy dn cho PLC v mch iu khin
Tiu chun IEC 60439 c cho trong bng sau
Bng tiu chun chn dy IEC 60439
Range of rate current

Conductor cross-sectional area

Ampe

mm2

AWG/MCM

1,0

18

12

1,5

16

12

15

2,5

14

15

20

2,5

12

20

25

10

25

32

10

Da theo bng tiu chun trn, vi h thng cc r le trung gian c dng ti

nh mc ca tip im l 5A, dng ti a chu c l 5A v dng qua cun
ht van in t l 9mA nn ta chn dy dn mch iu khin cho r le v van c
tit din 1 mm2.
B ngun ca PLC rockwell c cng sut 110VA 240VAC, chu c dng ti
a l 2A 5V v 0,8A 24V nn chn dy dn cp ngun nui cho plc qua ap
to mat l 2 x 1.5 mm2.
Chn dy dn u u vo ra PLC tng t nh chn dy cho r le trung gian.
3. Thit k s nguyn l
3.1. S nguyn l t in iu khin ( Bn v trang tip theo )
3.2. S u dy cho PLC ( Bn v trang tip theo )

4.1. M phng s dng phn mm Automation Studio

4.1.1. Phng php lu
a. Yu cu cng ngh ( nu phn u tin )
b. Thit k lu trng thi lm vic ca h thng
( Bn v trang tip theo )

c.

Lit k cc u vo ra cho PLC

Bng lit k cc u vo PLC
CC U VO

STT

a ch

K hiu

Chc nng

Local:2:I.Data0

start

Khi ng h thng

Local:2:I.Data1

stop

Dng h thng tin

Local:2:I.Data2

a0

CHT u hnh trnh Xilanh A

Local:2:I.Data3

a1

CHT cui hnh trnh Xilanh A

Local:2:I.Data4

b0

CHT u hnh trnh Xilanh B

Local:2:I.Data5

b1

CHT cui hnh trnh Xilanh B

Local:2:I.Data6

c0

CHT u hnh trnh Xilanh C

Local:2:I.Data7

c1

CHT cui hnh trnh Xilanh C

Local:2:I.Data8

Pht hin vt trn bn my

10

Local:2:I.Data9

d0

CHT u hnh trnh Xilanh D

11

Local:2:I.Data10

d1

CHT cui hnh trnh Xilanh D

12

Local:2:I.Data11

Sua chua

Sa cha khi h thng gp li

Bng lit k cc u ra PLC

CC U RA
STT

a ch

K hiu

Chc nng

Local:3:O.Data0

n xanh

Bt khi h hot ng

Local:3:O.Data1

XLAday

Xi lanh A y

Local:3:O.Data2

XLAthu

Xi lanh A thu

Local:3:O.Data3

XLDday

Xi lanh D y

Local:3:O.Data4

XLDthu

Xi lanh D thu

Local:3:O.Data5

XLBday

Xi lanh B y

Local:3:O.Data6

XLBthu

Xi lanh B thu

Local:3:O.Data7

XLCday

Xi lanh C y

Local:3:O.Data8

XLCthu

Xi lanh C thu

10

Local:3:O.Data9

n 1

Bt khi h gp s c 1

11

Local:3:O.Data10

n 2

Bt khi h gp s c 2

12

Local:3:O.Data11

n flash 1

Bin trung gian

13

Local:3:O.Data12

n flash 2

Bin trung gian

14

Local:3:O.Data13

n flash 3

Bin trung gian

d. Chy m phng h thng trn Automation Studio

( Bn v trang sau )
( File chy gi cho thy gio )

4.1.2. Phng php Ma trn trng thi

4.1.2.1. Yu cu cng ngh : Nh phn a mc 4.1.2
4.1.2.2. Qu trnh thit k theo phng php ma trn trng thi
a, Lit k bin vo ra
Tn hiu vo iu khin:
Tn hiu khi ng h thng START
Tn hiu dng h thng khn cp STOP
a0,a1,b0,b1,c0,c1,d0,d1 l cc tn hiu t cc cng tc hnh trnh
Tn hiu pht hin vt Sensor_P
Tn hiu ra:
A0, A1, B0 ,B1 ,D0, D1 l cc tn hiu ra iu khin cc xi-lanh A,B,C v
D.
Tn hiu iu khin cc n bo ang RUN hoc cnh bo.
b, S trang thi ca cc bin vo ra trong qu trnh
qu trnh tm cc phng trnh trng thi d dng hn chng em ch tm
phng trnh trng thi m t chuyn ng chnh ca c cu khi sn phm
khng li sau mi bng sung thm cc hot ng khi pht hin li.
Cc bin sau khi ti gin:
Bin vo: a0,a1,b0,b1,c0,c1,d0,d1
A0,A1,B0,B1,C0,C1,D0,D1
Sau khi ti gin cc bin tin cho vic tm phng trnh trng thi ta c s sau:

0000
00000000
D
+ C
C

+ B
B
+ A
A
abcd

+ D =

0000
1000
0001
0101
0111

10000000 01000010 00100000 00001000 00010000

(1)

(2)

(3)

(4)

(6)

0011
00000101
(7)

Bin vo
d

TT

Bin ra
d

d
c
+ +
A A B B

+
C C

a
1

(1)

(2)

(4)

(3)

(5)

(6)

Lp bng chuyn dch 1:

Lp bng chuyn dch 2:

T bng chuyn dch 1, nu ta em ra xc nh hm iu khin th hm iu khin thu c l
khng ti gin, v th ta phi ti thiu hm chuyn dch qua hai bc:
+ Nhp hng
+ Nhp trng thi tng ng
-

Nhp hng:
Tiu chun nhp hng theo iu kin sau: cc trng thi c th nhp li c vi nhau
nu s trng thi trong ct cng tn v ging nhau.
Nu mt trng thi n nh v mt trng thi khng n nh th ta u tin trng thi
n nh.
Nu mt trng thi n nh v mt trng th ta u tin trng thi n nh.
Nu mt trng thi khng n nh v mt trng th ta u tin trng thi khng n
nh.

Nhp trng thi tng ng:

Sau khi nhp c cc trng thi theo cc iu kin trn, chng ta c th tip tc
nhp cc trng thi cn li cho nhng trng thi tng ng, trng thi tng ng
l trng thi c tnh cht sau:
c cng tn hiu ra.
Khi chuyn t trng thi ny sang trng thi khc ko theo cng th t chuyn
gi tr u ra.

Bng truyn trng thi 2:

d

d
c

b
a

(2
)

(4
)

(5
)

(3
)

(6
)

(1)

Nhn bng trng thi ta s thy trong bi ton ny khng cn bin trung gian.

Hm iu khin cho cc bin ra:

Ma trn trng thi cacno cho bin ra A0:
d

d
c

b
a

0 0


Hm iu khin bin ra A0: A0= d c b a

Ma trn trng thi cacno cho bin ra B0:

d

c
b

0 0

Hm iu khin bin ra B0: B0 = a b c d

Ma trn trng thi cacno cho bin ra C0:

d

c
b

1 0

Hm iu khin bin ra C0: C0 = b. c

Ma trn trng thi cacno cho bin ra D0:

d

c
b

0 0

Hm iu khin bin ra D0:

D0 = A1

Ma trn trng thi cacno cho bin ra A1:

d

d
c

b
a

0 0

Hm iu khin bin ra A1:

A1 = a

Ma trn trng thi cacno cho bin ra B1:

d

d
c

b
a

0 1

Hm iu khin bin ra B1:

B1 = a .c.b

Ma trn trng thi cacno cho bin ra C1:

d

c
b

0 0

Hm iu khin bin ra C1:

C1 = a .c b

Ma trn trng thi cacno cho bin ra D1:

d

d
c

b
a

0 0

Hm iu khin bin ra D1: D1= C1

Vy, ta c h cc hm trng thi cho cc bin ra nh sau:

A 0=a 0 b 0 c 0 d 0
A 1=a1
B 0=a0 b0 c 0 d 1
B 1=a 0 c1 b1
C 0=c 0 b1
C 1=a0 c 1 b 0
D 1=C 1
D 0= A 1

Mch m phng cng ngh trn Automation Studio 5.0 bng ngn ng Ladder :

Sau khi tm c cc hm trng thi ta tin hnh v mch m phng v b

xung cc trng thi ph khi xy ra trng hp pht hin sn phm li.
Ch :
Mch m hng b xung thm chc nng m sn phm t v li sau mi
ca lm vic. (tc l cc sn phm t v li s m v lu vo 2 bin m ca
C5:1 v C5:2 ).
Mch m phng trn Automation Studio 5.0:
(Bn v trang sau)

M t hot ng ca mch m phng :

mch hot ng ta cn bm nt Sensor_P sau nhn nt START thay cho
cm bin P, hai iu kin ny lm cho xi lanh A y sn phm vo v tr nh
trc sau khi y xong th A li v ng thi M i xung sau khi M ht hnh
trnh i xung th xi lanh B tin ra:
Nu trong qu trnh tin ra ny, ta gim m van xung 0 ( gi lp trng
hp B b vng do sn phm khng c rnh) trong lc ny khi timer T2:1
m nu qu 5s th n bo li bt, tt c cc xi-lanh thu v v khi m sn
phm li C5:2 tng bin m ln 1.Tip theo nu ngi ng my ly vt ra
khi my, t vt khc vo sau n START th my s tip tc chu trnh
kim tra
Nu trong qu trnh tin ra ny, ta gi nguyn m van ca 2 van tit lu 1
chiu ca B l 50% th c ht mt chu trnh test th bin m sn phm t
trong C5:1 tng thm mt n v ng thi tt c cch xi-lanh v v tr ban
u tr cho ngi ng my ly sn phm ra, t sn phm mi vo v n
nt START th my s thc hin kim tra li vt

4.1.3. Phng php Grapcfet

4.1.3.1. Yu cu cng ngh : Nh phn a mc 4.1.2
4.1.3.2. Lp cc GRAFCET :

 Lp GRAFCET I:

nh ngha cc tn hiu iu khin v tn hiu ra:

Xi lanh A v cc cng tc hnh trnh a0, a1

A0: Tn hiu iu khin xi lanh A chuyn ng i ra
A1: Tn hiu iu khin xi lanh A chuyn ng thu v
a0 :Tn hiu xc nh v tr u ca pittong trong xi lanh A
a1 :Tn hiu xc nh v tr cui ca pittong trong xi lanh A

Xi lanh B v cc cng tc hnh trnh b0, b1

B0: Tn hiu iu khin xi lanh B chuyn ng i ra
B1: Tn hiu iu khin xi lanh B chuyn ng thu v
b0: Tn hiu xc nh v tr u ca pittong trong xi lanh B
b1: Tn hiu xc nh v tr cui ca pittong trong xi lanh B
Xi lanh C v cc cng tc hnh trnh c0, c1
C0: Tn hiu iu khin xi lanh C chuyn ng i ra
C1: Tn hiu iu khin xi lanh C chuyn ng thu v
c0: Tn hiu xc nh v tr u ca pittong trong xi lanh C
c1: Tn hiu xc nh v tr cui ca pittong trong xi lanh C
Xi lanh D v cc cng tc hnh trnh d0, d1
D0: Tn hiu iu khin xi lanh D chuyn ng i ra
D1: Tn hiu iu khin xi lanh D chuyn ng thu v
d0: Tn hiu xc nh v tr u ca pittong trong xi lanh D
d1: Tn hiu xc nh v tr cui ca pittong trong xi lanh D

Lp GRAFCET II:

4.1.3.3. Chuyn GRAFCET II thnh ngn ng ladder :

Phng php chuyn:

Ly v d qu trnh chuyn trng thi t trng thi 7 sang trng thi 8 v 9

GRAFCET II:
iu kin ngt trng thi 7 v chuyn sang trng thi 8, 9 l trng thi 8,
9 c thc thi nh hnh di:

Cc chuyn trng thi khc cng thc hin tng t.

Sau khi chuyn ta c on chng trnh ladder sau:

 4.1.3.4. Mch m phng trn Automation Studio 5.0 bng ngn ng Ladder:

Sau khi tm c cc hm trng thi ta tin hnh v mch m phng v b

xung cc trng thi ph khi xy ra trng hp pht hin sn phm li, ta c
chng trnh ladder
( c bn v trang sau)
Ch :
Mch m hng b xung thm chc nng m sn phm t v li sau mi
ca lm vic. (tc l cc sn phm t v li s m v lu vo 2 bin m ca
C5:1 v C5:2 ).