1、TDG-seriesRice-mixing PC Control SystemInstructions ManualZhangzhou Yujie Electronics Co., LtdTDG-P Series Continuous Auto Rice-mixing Machine1. OutlineTDG-P Series Continuous Auto Rice-mixing Machine is a kind of intelligentized equipment that uses the latest electronic machinery technique and can

2、weigh and control the materials automatically during the production. It can be in blending production with kinds of materials (more than two kinds) and widely apply to rice process, feed, medicine, and chemical industry etc.The series of products use the industrial control computer and variable-freq

3、uency control system, which has the charateristics of advanced technique, rational construction, easy operation, convenient installation, stable and reliable running etc. It is a kind of ideal equipment for accomplishing to continuous measuring and auto blending production.2. Main characteristics an

4、d technical parameters(1) It provides the instantaneous/total flow data of kinds of materials and has the function of auto alarm and shutdown etc in starving procedure.(2) The belt mode quantitative feeding machine configures the high-accurate weighing load cell, electronic digital instrument. It ca

5、n be set the proportion at will and will not damage the materials.(3) It uses the frequency control transmission system that can be in manual feed and auto control feed etc.(4) The human-computer interface is easy to operate.(5) Main technical paramters: different series have a little differeces, se

6、e the advertisement of our company in detail.3. Work principleThe auto matching system is composed of multiple electronic belt scales, conveyor and PC console etc. When the materials go through the electronic belt scale, the high-accurate weight sensor transforms the weight variation to the correspo

7、nding electronic signal, and collects the weight data and the RPM pulse tested by the sensor and sends them to the computer on the con sole. The computer figures out the instantaneous flow and total flow and compares the instantaneous flow with the dema nded value, and sends out con trol sig nal to

8、freque ncy con verter accord ing to the calculated differenee. To achieve the purpose of auto matching, the frequency conv erter auto adjusts the tran sport ing speed of belt scales to make them work with the matching ratio at the same time. If it is necessary to do manual running, you can set and r

9、un by using the manual switch and speed gover ning pote ntiometer on the con sole. Whe n starv ing, the displayer will appear alarm in dicati on and output auto shutdown control signal, the principle diagram (single station) is shown in Picture 1.Picture 1 Priciple diagram4. Belt scaleThe belt scale

10、 of TDG-P syetem is mainly composed of load cell, frequency converter, weighing instrumnet, feed belt and hopper etc. This kind of structural style has the advantagesof high weighing accuracy, smooth speed governing, small and light, easy to adjust and maita in etc. There is a gate on the hopper tha

11、t is used for regulating the thickness of materials. The structure is shown in Picture 2.Instantaneousflow measuring: when the feed belt runs with speed V and the materials on the belt is distributed evenly, the instantaneous flow is:F=V*G/L=Kc*G*VG is the weight displayed by the in strume ntV is th

12、e lin ear velocity of belt (measured by CD in strume nt)Kc is the tran sport coefficie nt of belt scale Kc=1/LL is the effective len gth that belt scale bear the materials5. PC con soleThe con sole is used for measuri ng the weight and detect ing the RPM. It figures out the flow of materials on belt

13、 scale and compares with the theorical flow set by user, and output 0-10V voltage according to the differenee. It is also used for controlling the variable-frequency governor in belt scale, and real time control the transsimision speed of belt scale to make the flow of belt scale be equal to the the

14、orical value, to accomplish to con trolli ng the qua ntitative feed ing. The con sole controls multiple belt scale at the same time so that can accomplish to the rice-mixing con trol accord ing to the team product ion and match ing.The con sole also matched the manu al/autc running switch, con veyor

15、 starti ng and running butt on, auto running light, and ex-error alarmi ng light. It also has manu al-r unning freque ncy-adjust pote ntiometer, eve n though there is no computer, it can also work by manual operati ng.6. Preparation before production(1) Check each connect lines if correct, when read

16、y, turn on the main supply of con trol cab in et.(2) Tur n on the in dustrial con trol computer, now the computer starts, start the software mai nform.(3) Turn the manual/autc corresponding to each station of control cabinet tomanual position. Calibrate the weight display of CD instrumnet and set FU

17、N11 in 2.(5) Calibrate the linear speed V of belt scale.(6) Set up the parameter of team product ion and material matchi ng parameter in each stati on.(7) Set up the alarm parameter and PID control paramter.7. Production steps(1) When all the preparation is ready, connect the power supply; turn the

18、pote ntiometer knob to minimum and press starti ng butt on of all the con veyors to make them start to work. And then open the hopper gate, widen the gate which has high matchi ng ratio, in con trast, n arrow the hopper gate.(2) First rotate the potentiometer manually to go constant production befor

19、e worki ngTurn the manual/autc switch on the operating panel to manual position, now it comes in to manual operat ing state. Regulate the pote ntiometers corresponding to the each belt scale slowly until the frequency value of converter reaches to the need, then the belt scale will run with the sett

20、ingCanlrol madB AlfIOfreque ncy.(3) Whe n the belt is start in g, it comes to auto product ionChoose Auto in the mainform and click Boot-strap，and then turn the manual/auto switch on control operating panel to auto position, now the belt scale starts to run automatically. The computer will display t

21、he corresp onding proporti on coefficie nt, theorical flow, real time weight of each belt scale, instantaneous flow and RPM, the converter displays the frequency value. When the material weight value changes, the frequency value will also change, and the transsmision speed of belt sclae will follow

22、to change, to accomplish to feeding pro rata.(4) Ex-error alarm function:When one material overruns error (so-called overrun error is that the highest output frequency of belt scale or output frequency or output voltage is less than limited value, or the weight exceeds the limited value) and exceeds

23、 the limited time, the computer will appear alarm indicate for words, the alarm light on the console is on, the buzzer rings, to make operator pay attention or do manual intervention.Disposal method: when the starving causes ex-error, you can rise the hopper gate or power on until the materials incr

24、ease; when the too heavy materials cause the too low frequency and send out the alarm, you can lower the hopper gate or change the matching ratio.8. Zero adjust and quantizing of belt scale (operation CD940 instrument)(1) Zero adjust:First clear the things on the belt scale, and then press【Set】one t

25、ime to display “FUN1,press【+】one time to display “FUN2, and pres【s Enter】to display internal code, press【 - 】after several seconds the swing light is off. And after several seconds displaying “0.00it returns to display internal code, so it is successfully reset. Press 【 Enter】 one time to quit zero

26、adjust function and it displays “0.00, the reset operation is completed to date.(2) Weight adjust:First set up the weight value of balance for calibration, and pre【ssSet】one time to display “FUN1, press【 Enter】to display “000.00. Suppose the balance weight is 20KG, press【Shift】one time and press【+】t

27、ow times to display “20.00, and press 【 Enter】to save the setting value and it displays“FUN1. Now press【+】one time todisplay FUN2 ，a nd press【En ter】 to display in ternal code, now clear the leftover in scale body and pres【-】 to reset after several seconds theSwing light is off, it will retur n to d

28、isplay internal code after display ing 0.OO several sec on ds, so it is successfully reset and the reset operation is completed to date; now put the 20KG balanee onto the scale body and keep it steady without shaking, (now the internal code also in creases a certa in value accord in gly, if the inte

29、rnal code dicrease in stead, it shows that the sig nal wire of sen sor is oppositely conn ected, just excha nge) preish to do quantization after several seconds the Swing light is off, it will return to display internal code after several seconds displaying20.00，the quantizingoperation is completed

30、to date. Press 【Enter to quit weight adjust function and it displays 20.00，now take away all the balances, the instrument displays 00.00，it shows that the qua ntiz ing is successful, or operate once more.9. RPM test of the belt scaleClick the Settings in the menu bar of the computer mainform, it app

31、ears the pull-down menu (the right picture), choose Belt scale transport coefficient setting and it appears the in terface in the followi ng picture:< FormlSEttdlLgg lTeas product leu and. Wch®0.0Picture 4Alan settingd)FID paramet&T settinEfE)Sav逞 cizrejit output vals 咼 dripriilfU)Total

32、flor settiug(y)Saved the curren'E total flor(W)Reset passTord(f)CIe-bt the pas sword saved in bemtt Exit 他j rPicture 5(1) Use the speed test function to test the speed: (tick Win the left-hand corner of Picture 5).匡亟J Picture 6Set Kn value of each scale in 1, as followi ng picture shows:No.iseKn

33、： 皿No. 2 険 000阪3臥|o'oo(rNo. 4 ScabIoTglo0.00 1Weight:set flow:Instan-lafWQGonverbcn output:Belt sp«ed :0.000.00Picture 7Speed test formula: the belt scale speed V=K*speed test data of the in strume ntWhen the parameter is set up and saved, retur n the mainform, now turn the Manual/auto to m

34、anual, turn on the power of No.1 scale, rotate the manual pote ntiometer of No.1 scale and keep in one positi on to make belt RPM constant. Now, see how much the belt running speed (the right picture) is on the mainform. For instanee, the displaying value V1=8m/s, record this value, the correspondin

35、g Kn is 1; and then manuallymeasure the time T that the belt sclae takes a turn cost by stopwatch (measure it more times and get the average value), suppose T=8 sec on ds, the belt perimeter L1 is 3.2 meter, so the real linear speed V2=L1/T=3.2/8=0.4m/s, and the real Kn value should be: Kn=real li n

36、ear speed V2/display speedV1=0.4/8=0.05, as a result, cha nge the Kn value of No.1 sclae (Picture 4 shows) to 0.05, and measure the Kn value of other stati on by the same way.(2) The belt RPM is converted by variable-frequency voltage: (not tick廠曲舉旳曲Picture 9When can cel V,the Kn value will auto cha

37、 nge to the corresp onding value. Setthe Kn value in 1, as the followi ng picture shows:No. 2 Scale|oOOQNa. 3 Seek|d oooninPicture 10The calculati ng method of Kn value is the same as the one of speed test, refere nee to the previous part.Speed calculating formula: running speed of the belt sclae V=

38、Kn2*RPM ame nd*variable-freque ncy output valueGen erally speak ing, the RPM ame nd is set in 1, just ame nd it whe n there exists deviatio n betwee n the tested speed and real value, as the picture shows:RPM amend60Hz 50Hz4DW30H;2QHz10Hz|o oo|o?oa |q?qq|5?qqPicture 1110n troducti on of machi ng con

39、 trol softwareThe match ing con sole uses the in dustrial con trol computer, if coordi nates with the control software developed by our company, it can accomplish to controlling the parameter sett ing, data display and con trol sig nal output, and achieve the purpose of auto maichi ng con trol.The m

40、ai n worki ng in terface of the con trol software is show n in Picture 12:F orm!Ttfutfti pttnljclicri：Ho. 1 ScaloRCdil廣 MamfllHall -ldeoG!-L：iafKg7nP0 How iflM workimeAll Roir島厲mi ir Krumon csmmiricaien etron intuiirnant san'unmDGn mor1 利倒rurneni ocerai仃3W*311 巧uncati&n wror*co0.00：-0 0Kg/aS

41、«i (low ；low : Bfri 9|»«: CgiiWtKmi oulpul:TDrVb1 ScqId-如t阿amng0 30irr/tfi I jm I ill H Gir I n>|*1,0和MdO師"=5 2LPicture 12 Mainform of the con trol softwareMai nform It can display the work ing parameter set by user: team product ion and match ingratio of each belt scale are s

42、hown in Picture 13:Plum prnrtii：r*ferT-lliUDNd 1-： h. j m：iT71No 3 SrGflCPicture 13 It can dynamically display the running data of belt scale: the weight value, setting flow value, in sta ntan eous flow value, belt running speed value and variable-freque ncy output value of each belt scale are show

43、n in the followi ng picture:Weight :Sol fto>v :InElartsnaoufi flow:Soli «paod -CwiM#rtter cxitpiX :Picture 14 It matches the manual and auto butt on and boot-strap butt on for users:Cantral mode' MvdUil AuioPicture15There is the pull-down menu in the mainform for users to choose, as Pict

44、ure 16shows:Picture 16 Pull-dow n menu(1) Team product ion and match ing sett ingBefore worki ng, the team product ion should be set accord ing to the real situati on, and the match ing of belt scale must be set with user's tech ni cal dema nd, but don't outstrip the work ability of the equi

45、pme nt. Click the Sett ing butt on in the mai nform (Picture 17) and it appears that Picture 18 shows:Picture 18When the above parametersare all set up and the flow unit has been chosen, clickCon firm to save the setti ng parameter and it auto gen erates the sett ing flow of eachbelt scale (the righ

46、t picture).(2) Belt scale transport coefficient setting:Click the Settings in the mainform and chooseBelt scale tran sport coefficie nt sett in g, it appearsthat Picture 20 shows:r' FormlSettings (5)Team production and latch(L)Alan settiup(JPID parametct 3citing(P)Save currmt output Yfl忻 m iPict

47、ure 20Convertkxi output:0.00Belt scale Kc value: before the matchi ng is take n in use, you should check the Kcvalue to en sure the accuracy dema nd of total flow. Kc calculati ng formula: Kc=1/L.L is the effictive len gth that the belt scale bear the materials, n amely, the dista ncefrom feed ope n

48、ing to discharge hole.Picture21When in measuring, the effective length L will cause man-made error and measuring error, so you should do fine-regulation to Kc. The regulating method is as followi ngs:After the belt scale is reset, first figure out a Kc value according to the measuring value, and put

49、 it in the parameter settings of main program. Now turn theManu al/auto on the con sole to manual and turn on the power of No.1 scale motor, rotate the manual potentiometer of No.1 scale and keep in one position to make the belt RPM constant. And then put a certain weight G1 materials into the hoppe

50、r until the G1 materials are all sent out. Now check the total value G2 displayed by the instrument if be equal to G1, if not, when G2v G1, increase Kc value; when G2> G2, dicrease Kc value. Adjust it until G2=G1, the Kc value calibration is completed. Calibrate the Kc value of other belt scales

51、by the same way.The RPM coefficie nt and RPM ame nd value should be set by experieneed technician.Reference to Part 9 to see the detail.(3) Alarm settingUsers can set the upper and lower limit parameter of belt scale and frequencyconv erter and alarm con trol parameter accord ing to the actual situa

52、tion. Click the Setting§' in the mainform and choose Alarm setting in Pull-down menu, it appears that Picture 24 shows:e FormlSTttinga(3)Team pToduction and «atch 囘Heli icaltAL a ra setting (TjPicture 23Picture 24Choos ing the weight alarm and the n shutdow n will be favourable for pro

53、tect ing the system if it appears unusual in production.(4) PID parameter settingPID parameter is used for regulating the stability of variable-frequency control, regulate this parameter properly if the control is unstable or in shake. Click the Settings in the mainform and choose PID paramter setti

54、ng in pull-down menu, it appears that Picture 25 shows.Proporti on coefficie nt Kp, i ntegral coefficie nt Ki and differe ntial coefficie nt Kd are the three important parameters in PID calculation, the larger they are set, the more timely the flow will trace, but the fluctuati on will be large and

55、easy to cause shake; the smaller they are set, the slower the flow will trace, but the fluctuation will be small, the product ion will be stable and not easy to cause shake.The con trol cycle Tcy is the time in terval in the sec ond con trol. It is gen erally set in 2-3 sec onds.The control step lim

56、it is the max. value everytime the frequency output, the smaller it is set, the more favourable it will be for avoiding the control system causing shake. It is gen erally set in 2-4 Hz.(5) Set output original valueClick the Settings in the mainform and choose Set output original value inpull-dow n m

57、enu, it appears that Picture 26 shows:Output original value: just choose Auto in the program mainform and click Boot-strap，it is the freque ncy value that first output whe n the system starts to run automatically. You can make timelag according to the setting delay time. When the main program runs,

58、only the Manual/auto on the outer electric control cabinet is turn to auto can the system run automatically, but if so, PID will start to calculate from 0 and always cause shake and fluctuation, which make the system unstable. Therefore, setting the output original value can solve this problem.(6) Total flowClick the Settings in the mainform and choose Total flow setting inpull-dow n menu, it appears that the follow ing picture s