Manukau Institute of Technology
School of Professional Engineering
Automation 527.613
Project 2 Semester 1, 2019 – Touch Screen, PLC, VFD & Ethernet. The project will be due by 8am, 10 Jun 2019. This project leads to a project test. The project demos in classroom and project test have a weighting of 15%.
Objectives
Develop a Rockwell PanelView Plus 1000 Touch Screen application by Rockwell FactoryTalk View Machine Edition (ME) to interface an RSLogix5000 programme and control the speed of Rockwell PowerFlex 40 Variable Frequency Drive (VFD) via Ethernet. An N/O StartPushButton is used to start a conveyor. The conveyor is driven by VFD at the following speeds: 50Hz for 10 seconds to bring wood logs to a band saw; while approaching the saw the conveyor is decelerated to a cutting speed of 20Hz for 20 seconds; and then the conveyor is accelerated back to 50Hz for 10 seconds to pull the logs off the saw. Stop the process immediately once an N/C StopPushButton is pressed.
The Touch Screen application is developed with the basic Pushbuttons (i.e. start, stop, forward, reverse, clearAllFaults, etc.). The Touch Screen functions also include status Indicators (i.e. ready, decelerating, accelerating forwarding, reversing, OK/Faulted, etc.) and numeric display of the conveyor speed. An alternate control by the PLC switches & PLC LEDs should also have been implemented.
Layout and operation
There will be graphics on each of the displays created, with indication and control as appropriate. A totally professional job is expected in every respect. All the important aspects of HMI displays will be taken into consideration. These include placement, sizing, data entry points, status indication, appropriate colour, etc. Display change buttons will be arranged along the bottom – everything as detailed. You have the flexibility to be inventive in your own way to add to the displays to improve usability but the basics as specified must be all there and functioning. You must comply with the specifications given.
Points to consider
Allow the operator to set all parameters, control and monitor all aspects of the system as detailed in this document. Allow Faults to be cleared and be truly “user friendly” for the operator. Use any of the available programming languages such as Ladder Diagram (LD), FBD or SFC or any combination for control.
VFD Operation can be summarized as follows:
Pushbuttons:
• Start
• Stop
• Forward
• Reverse
• Press to Clear Fault
Further Push Buttons to select accel 3 or 5 seconds and decel 3 or 5 seconds (in either direction – example this means if 3 seconds is selected for accel this is the same forwards and reverse, likewise with decel). It must be obvious to the operator which selection has been made.
Status indicators:
• Ready (grey/green)
• Accelerating (grey/green)
• Decelerating (grey/green)
• Okay/Faulted (grey/red)
Further status indicators to display of direction – is the conveyor running forward (clockwise looking at the gearbox output shaft), or reverse, (anti-clockwise) and display of the speed (Hz) in each direction
Gauge
A “centre zero” gauge to indicate the speed and direction.
Remember to set appropriate limits on all data entry points (min max) on all screens.
Note: the above description is not fully detailed. You must read it carefully and consider all possibilities of control from the user’s perspective, to produce a really good project. Be innovative, be professional and be thorough.
Requirements:
• To develop a RSLogix5000 program;
• To design and develop a Touch Screen application using FactoryTalk View ME;
• To demonstrate your working project in the class;
• To prepare and sit a project test.
Other Notes which may be helpful:
Use a consistent size of buttons say 40 H x 80 W pixels.
Distinguish buttons from multi-state indicators by making the appearance different. Use mainly neutral colours – say keeping red for warnings and stop buttons.
With the numeric displays note that the field length must include the sign (-) and any decimal point. The gauge is similar to FTViewSE and note min -100 to max 100 will give a zero centered gauge.
In terms of numbers relative to frequency, 252 in the register for frequency = 1 Hz.