Chapter One

Introduction

Introduction
1.1Mechatronics definition
Mechatronics is the combination of mechanical engineering ,
electronic engineering , computer engineering . Software engineering
, Control engineering , and system design engineering in order to
design , and manufacture useful products . Originally , mechatronics
just included the combination between mechanics and electronics ,
hence the word is only combination between mechanics and
electronics.

Fig()

1.2 Mechatronics Applications:

Machine vision
Automation and robotics
Servo-mechanics
Sensing and control system
Expert systems
Industrial goods
2

Microcontrollers / PLCs
Medical mechatronics , medical imaging systems
Structural dynamic systems
Transportation and vehicular systems
Mechatronics as the new language of the automobile
Diagnostic , reliability and control system techniques

1.3 Control systems

Interconnection of components forming system configuration which
will provide a desired system response as time progresses . the key
characteristic of control is to interfere , to influence :

1.3.1 Functions of a Control System:

1. Measurement: This is essentially an estimate or appraisal of the
process being controlled by the system
2. Comparison: This is an examination of the likeness of the
measured values and the desired values
3. Computation : This is a calculated judgment that indicates how
much the measured value and the desired values differ and what
action and how much should be taken.
4. Correction :This is ultimately the materilisation of the order for the
adjustment .

1.3.2 Hardware of a Control System :

Examining the automatic control system, it is found that it contains
the following hardware
Sensor : a piece of equipment to measure system variables. It
serves as the signal source in automatic control
Controller : a piece of equipment to perform the functions of
comparison and computation
Control Element : a piece of equipment to perform the control action
or to exert direct influence on the process

1.3.3 Software of a Control System:

Associated with a control system are a number of different types of
variables.
3

First we have the Controlled Variable. This is the basic process value
being regulated by the system. It is the one variable that we are
specially interested in - the outlet water temperature in the example
above. In feedback control the controlled variable is usually the
measured
variable.
An important concept related to the controlled variable is the
Setpoint.
This is the predetermined desired value for the controlled variable.
The objective of the control system is to regulate the controlled
variable at its setpoint. To achieve the control objective there must
be one or more variables we can alter or adjust. These are called the
Manipulated
VariablesConclusively, in the control system we adjust the
manipulated variable to maintain the controlled variable at its
setpoint. This meets the requirement of keeping the stability of the
process and suppressing the influence of disturbances.

1.4 Motivation to our project:

The main factor at dosing of components and micro components,
which defines the quality of the dosing process, is the exactness of
measurement the weight by the electronic machines
Dosing of materials from set of main silos to weighing containers
placed in various location of a plant; bulk and fine dosing; automation
of liquid dosing processes; possibility of applying a system algorithm
for dosing random liquid substances dosed in a forced way. This
project is suitable for many industrial applications in which costeffective weight measurements have to be performed with little
engineering overhead. This set is particularly suitable if additionally
automated logging functions are required in the framework of the
measurement

1.5 Aim of the Project:

1- Studying the system and estimating its problems .
2- Studying the performance of the system .
3-Studying the dosing and mixing control system using PLC & HMI
4-Applying simulation programs on the system for studying the
positives & negatives of design
5-Redesign and rebuild the system based on the mechatronics
application.

Chapter Two
Project description

Introduction
In this chapter we will talk about our project objectives ,components
and how to reach to our objective by using these components

2.1 Project description

2.1 System description

Fig(2-1)

2.2 system description:

The system consists of two stages (mixing process and dosing process)
The first stage is mixing process which three liquids are poured from three
different tanks in specific percentages and specific weight by the operator
using HMI touch screen into mixing tank . Then the mixing process takes a
place for a specific period of time
At the second stage : The conveyor runs under the mixer vertically with the
mixer solenoid valve and the proximity sensor works as a detector for the
empty product container under the mixer solenoid valve to dose it.
For accuracy assurance of the process the container has weighted within
the dosing process by loading it on a load cell lifted by double acting cylinder
which is controlled by pneumatic solenoid valve and the dosing starts until
getting to the required value of the product which the operator was entered
by HMI touch screen. The load cell works as a weight sensor which gives a
feedback of the current product weight.
Then , by getting to the required weight the mixer solenoid valve is closed
the pneumatic solenoid valve brings the load cell down and the dosed
container on the conveyor which moves it to make the system ready for the
next dosing process .
The other function of the proximity sensor is to count the number of
the products

2.3 Power supply [PS 307; 5 A power supply

module]:
2.2.1 Properties of the PS 307; 5 A power supply module:
Output current 5 A
Output voltage 24 VDC; short circuit-proof, open circuit-proof
Connection to singlephase AC mains
(rated input voltage 120/230 VAC, 50/60 Hz)
Safety isolation to EN 60 950
May be used as load power supply
8

Fig(2-2)

2.3.1 Wiring diagram of PS 307; 5 A

Fig(2-3)

2.4 The controller

The main controller of the system is the plc type
S7314C-2DP
Technical specifications of CPU 314C-2DP

01

2.5 HMI [Human Mahcine Interface] :

Fig (2-4)
HMI stands for Human machine interface. HMI's are used as an
operator control panel instead of using an excessive amount of
hardware and also provides almost unlimited control and status of a
fully automated machine cell.

2.5.1 HMI Usage: Process visualization

Operator control of the process
Displaying alarms
Archiving process values and alarms
Process values and alarms logging
Process and machine parameter management

00

2.5.2 Siemens HMI Family

Micro Panels
Mobile Panels
Touch&Operaing panels
Panel Pcs
Pc(SCADA)

2.6 Proximity sensor :

Fig(2-5)

Model
no

G183A10NC

Detection Operating
distance voltage

10 cm Dc 10-30v

Output
method

Statue

NPN

No+Nc

02

Response Detection
time method

<2 ms diffusetype

2.7 Pneumatic cylinder

Fig (2-6)

03

2.8 Relay:

Fig(2-7)

Fig(2-8)

Fig(2-9)

04

2.8.1specification

RELAY, 3PCO, 10A, 24VDC, PLUGIN

Product Range: FINDER - 60 Series
Coil Voltage: 24VDC
Contact Current: 10A
Contact Voltage VAC: 250V
Contact Voltage VDC: Contact Configuration: 3PDT
Coil Resistance: 445ohm
Relay Mounting: Quick Connect
SVHC: No SVHC (16-Dec-2013)
Approval Bodies: BEAB, BSI, CSA, DEMKO, IMQ, RINA, SEMKO,
SETI, UL, VDE
Coil Current: 53.9mA
Coil Operating Lower Percent Limit: 80%
Coil Operating Upper Percent Limit: 110%
Coil Type: DC
Coil Voltage VDC Nom: 24V
Contact Current AC Max: 10A
Contact Current DC Max: 10A
Contact Current Max: 20A
Contact Voltage AC Max: 250V
Contact Voltage AC Nom: 250V
DC Coil Power: 1.3W
Dielectric Strength VDC: 2000V
External Depth: 36.2mm
External Height: 51mm
05

External Length / Height: 51mm

External Width: 32.5mm
Mounting Type: Plug-In
No. of Poles: 3
Nom Operating Power: 1.3W
Operating Temperature Max: 70C
Operating Temperature Min: -40C
Operating Time: 9ms
Relay Type: General Purpose
Release Time: 9ms
Series: 60
Switched Current Max: 20A

2.9 Load cell

2.9.1 Principle of operation
The basic component in each case is a special type of spring body.
The application of force elastically deforms the spring body. The
ohmic resistance of the strain gauges changes as a result

Fig(2-10)

Principle of operation, based on the example of a loaded bending

beam load cell
For each load cell, at least four strain gauges are connected together
as a complete Wheatstone bridge. The stretched or compressed
strain gauges are connected in such a manner that the positive or
negative resistance changes are summed to produce an overall
imbalance of the bridge.
06

The supply voltage is applied across one diagonal of the bridge and,
in the case of the sixwire connection method, also the sensor voltage
SENSE. The measured voltage is tapped across the other diagonal.
For a constant supply voltage EXC, therefore, the measured
voltage SIG changes proportionally to the introduced load. In
practice, load cells contain additional resistors for temperature
compensation and for zero-signal and characteristic-value
compensation.
Depending on their type and the requirements, these resistors can
be arranged at the input or output of the load cell.

Fig(2-11)

07

2.10 MICROMASTER 440:

Fig(2-12)

2.10.1What is the micromaster?

Micromaster is a type of 2p/3p motor driver called as an inverter it's
supply voltage could be 220v or 380v and it drives an Ac motor
which supply is 3p/2p That mean by a supply voltage of 220v a
motor of 380v supply could be operated.
The micromaster is a combination between a processor (cpu) ,
rectifier and the driver circuit.
The programming language for the cpu is the parameters that is
being downloaded to the inverter via basic operation panel (bop) or
by the starter software from the computer each parameter depend
on others to achieve the required task .

Parameter settings:
1) Parameters can be set using the BOP / AOP operator panels.
2) The Drive Monitor or Starter visualization programs.
The driver can be connected to the pc using
08

1) Serial communication rs232 module.

2) Profibus module

2.10.2 Micromaster 440 specifications:

09

Fig(2-13).

2.10.3 Setting the inverter to frequency supply:

21

Power terminals layout:

Input supply voltage

220 v ac

Output terminals 380v

20

2.10.4 Connection between the motor and mm440:

Controlling the micromaster via Basic Operator Panel (BOP).

22

2.10.5 Basic commissioning (getting started):1)Reading Motor Name Plates

23

The parameters of the motor should be set :

24

25

2.11 ROFIBUS cable:

Fig(2-14)

PROFIBUS (Process Field Bus) is a standard

for fieldbus communication in automation technology and was first
promoted in 1989 byBMBF (German department of education and
research) and then used by Siemens. It should not be confused with
the PROFINETstandard for Industrial Ethernet. PROFIBUS is neither
an openly published nor a royalty-free protocol, as opposed
to MODBUS.

2.11.1ROFIBUS Networks:
PROFIBUS networks were specially designed for use in an industrial
environment and one of their main features is their degree of
immunity to electromagnetic interference resulting in high data
certain guidelines must ,integrity. To achieve this degree of immunity
be adhered to when configuring electrical network
26

2.11.2 Parameters:
The following parameters must be taken into account when planning
an electrical network
1.The transmission rate required for the task (within a network, only
one uniform transmission rate can be used)
2.The required number of nodes
3. The type of network components required (bus terminals, bus
connectors connecting cables)
4. The LAN cables to be used
5. The required segment lengths
6. The electromagnetic and mechanical environment of the cabling
(for example surge voltage protection, cable route surge voltage
protection, cable route)
7.The number of RS-485 repeaters between any two DTEs is limited
to a maximum of 9
8.Increasing the overall span of a network by using repeaters can
lead to longer transmission times that may need to be taken into
account when configuring the network

2.11.3 Use in a networked system

The following illustration shows the connection in a networked S7
system (MPI/DP) network containing 2 or more network nodes

Fig(2-15)

27

2.12 RS232 Cable:

Fig(2-16)

RS-232 is simple, universal, well understood and supported but it

has some serious shortcomings as a data interface. The standards to
256kbps or less and line lengths of 15M (50 ft) or less but today we
see high speed ports on our home PC running very high speeds and
with high quality cable maxim distance has increased greatly. The
rule of thumb for the length a data cable depends on speed of the
data, quality of the cable.
Data is transmitted and received on pins 2 and 3 respectively.
Data Set Ready (DSR) is an indication from the Data Set (i.e., the
modem or DSU/CSU) that it is on. Similarly, DTR indicates to the
Data Set that the DTE is on. Data Carrier Detect (DCD) indicates that
a good carrier is being received from the remote modem.
Pins 4 RTS (Request To Send - from the transmitting computer) and
5 CTS (Clear To Send - from the Data set) are used to control. In
most Asynchronous situations, RTS and CTS are constantly on
throughout the communication session. However where the DTE is
connected to a multipoint line, RTS is used to turn carrier on the
modem on and off. On a multipoint line, it's imperative that only one
station is transmitting at a time (because they share the return phone
pair). When a station wants to transmit, it raises RTS. The modem
turns on carrier, typically waits a few milliseconds for carrier to
stabilize, and then raises CTS. The DTE transmits when it sees CTS
28

up. When the station has finished its transmission, it drops RTS and
the modem drops CTS and carrier together.
Clock signals (pins 15, 17, & 24) are only used for synchronous
communications. The modem or DSU extracts the clock from the
data stream and provides a steady clock signal to the DTE. Note that
the transmit and receive clock signals do not have to be the same, or
even at the same baud rate.
Note: Transmit and receive leads (2 or 3) can be reversed depending
on the use of the equipment - DCE Data Communications Equipment
or a DTE Data Terminal Equipment.

29

2.13 PC Adapter USB:

Fig(2-17)

The PC Adapter USB is compatible with USB V1.1 and satisfies the
requirements for "Low-Powered USB devices. The SIMATIC PC
Adapter USB supports the energy saving mode (hibernate mode)

2.13 .1 Function
The SIMATIC PC Adapter USB connects a PC to the MPI/DP
A slot is not required in the interface of an S7/M7/C7 system via USB
PC, which means that the adapter can also be used for nonexpandable PCs such as notebook.

31

Fig(2-18)

30

32

2.14 Solenoid valve:

2.14.1 Solenoid valves operational principle:

A-Input side
B-Diaphragm
C-Pressure chamber
D-Pressure relief conduit
E-Solenoid
F-Output side

Fig(2-19)

2.13.2 Specification:
Type of Solenoid Valve
Inlet Port Size
Outlet Size/Type
Flow Direction
Installation
Voltage

Single
3/4" BSP Male
11.5mm hose tail outlet
90 angle flow
Universal Fitting
230vAC 50Hz _ 6w

33

2.15 SIMATIC S7-300

SIMATIC S7-300: The modular controller for innovative system

solutions in the manufacturing industry SIMATIC S7-300 is the bestselling controller of the Totally Integrated Automation spectrum with a
host of successful reference applications worldwide from the most
varied industrial sectors, such as:
Manufacturing engineering
Automotive industry
General machine construction
Special-purpose machine manufacturing
Standard mechanical equipment manufacture, OEMs
Plastics processing
Packaging industry
Food, beverages and tobacco industries
Process engineering
The SIMATIC S7-300 has been designed for innovative system
solutions with the focus on manufacturing engineering, and as a
universal automation system, it represents an optimal solution for
applications in centralized and distributed configurations:
34

 The ability to integrate powerful CPUs with Industrial

Ethernet/PROFINET interface, integrated technological functions, or
fail-safe designs make additional investments unnecessary.
The S7-300 can be set up in a modular configuration without
the need for slot rules for I/O modules. There is a wide range of
modules available both for the centralized and the distributed
configuration with ET200M.
The Micro Memory Card as a data and program memory
makes a backup battery superfluous and saves maintenance costs.
In addition, an associated project, including symbols and comments,
can be stored on this memory card to facilitate service calls.
The Micro Memory Card also enables simple program or
firmware updates without a programming device.
The Micro Memory Card can also be used during operation for
storing and accessing data, e.g. for measured value archiving or
recipe processing.
In addition to standard automation, safety technology and
motion control can also be integrated in an S7-300.
Many of the S7-300 components are also available in a
SIPLUS extreme version for extreme environmental conditions, e.g.
extended temperature range (-40/-25 +60/+70 C) and for use
where there is corrosive atmosphere/condensation.

35

2.16 CPU 314C-2DP:

The layout

36

(1) For setting the line voltage

(2) Mode selector
(3) Mounting rail
(4) Programming device with STEP 7 software
(5) PG cable
(6) Connecting cable
(7) Clamp for strain relief
(8) Power supply ON/OFF

37

Chapter Three
Mechanical Design and
Construction

38

Introduction
This chapter consists of two parts .In the Mechanical part , we will
talk about design of all components in our mechanical .
In the electronic part, we will take a look in a load cell principal of
operation , signal conditioning , calibration details , proximity ,
solenoid valves , relays and pneumatic

3.1 The Mechanical Part

3.1.1 Introduction:
Our Component Dosing Using Weighing Control has been created as
an answer to market demand for precise and accurate batching of
products. Our dosing system is combined with external automatic
systems and mechanical part. The most suitable and effective
mechanics for our application is material handling.

3.1.2 What Is Material Handling?

The Material Handling Institute of America offers the following as
one definition of material handling: Material handling is the art and
science associated with providing the right materials to the right
place in the right quantities, in the right condition, in the right
sequence, in the right orientation, at the right time, at the right cost
using the right methods.

3.1.3 What Are the Major Objectives of Conveyor

Application?
Conveyors, as with all material handling equipment, do not add value
to the parts, products, or pieces that are being moved. They do not
shape, form, process, or change a product in any way. They are
totally processes of service and as a service they have an indirect
bearing on product cost as part of the overhead. The following is a
list of some of the major objectives of implementing conveyors:

Reduce actual manual handling to a minimum.

Perform all handling operations at the lowest reasonable cost.
Eliminate as many manual operations as possible.
Ease the workload of all operators.
39

 Improve ergonomic considerations for each operator.

Improve workflow between operations.
Provide routing options for intelligent workflow.
Increase throughput.
Carry product where it would be unsafe to do so manually.

41

3.1.4 Types of conveyor belts

According to the belt construction and target application, fabric
belts are distinguished in common conveyor belts and highly
specialized processing belts:

3.1.4.1 Conveyor belts

The term conveyor belt describes belts used to convey all kinds of
semi-finished and finished industrial products from one point to
another. They are mainly used in the handling of unit goods both in
the food and non-food production and packaging sectors and in
general materials handling for storage and distribution.

3.1.4.2 Processing belts

The term processing belts is used for belts that not only perform
purely conveying functions, but also have to fulfill important functions
in the actual work process. Typical examples of processing belts are:
Belts in the processing of unpacked and packed food
Printing blankets on textile printing machines
Cross lapper belts in nonwoven production
Prepress belts in particle board production
Treadmill belts, etc.

3.1.5 Belt conveyor components

System components
In its simplest form, a belt conveyor consists of a driving pulley (often
the head pulley), a tail pulley, the tensioning device, a conveyor belt,
and the supporting structure with the belt support (slider bed or
carrying rollers).

40

No.

Description

1
2

Driving pulley
Head or tail pulley (dep. on belt running direction

3
4
5

Slider bed
Carrying roller
Snub pulley

6
7

Deflection roller (idler)

Tension pulley (take-up pulley)

Carrying roller (on the return side)

Conveyor belt

10

Guiding pulley

Sign for driving pulley

Sign for tension pulley with tensioning direction

Belt running direction

If no additional information available the conveying system is

assumed as horizontal.
Many conveyor systems have additional components such as nose
bars, diverters, accumulators, belt tracking elements, cleaning
systems, etc.

42

3.1.6 Support structure, pulley and roller fixing

3.1.6.1 Support structure
The supporting structure must be rigid. It must not distort or fl ex from
the forces it is subjected to, i.e. belt tension, weight of the conveyed
goods, uneven floors, etc. Without a rigid structure, it would be
almost impossible to track the conveyor belt by conventional means
and keep it from running off under varying operating conditions (no
load/partial load/full load).
Furthermore, the supporting structure must be accurately aligned in
all planes. Checking for squareness should preferably be done by
measuring across the diagonals.

Fig(3-1)

3.1.6.2 Mounting of pulleys and rollers

Normally, the driving pulley is not adjustable and as with all other
pulleys and rollers, it must be aligned at right angles to the belt
running axis. Adjustable bearings are recommended for head, tail,
deflection and tension pulleys which are heavily loaded by the belt
tensile force.
As a general rule, only as many pulleys and rollers should be
installed as are necessary to carry and guide the belt. Each pulley
and roller can be the cause for belt running problems as well as for
accumulation of debris. Slotted mounts are suitable for less heavily
loaded rollers, e.g. for pivotable carrying rollers.

43

a.

b.

3.1.6.3 Belt support

Slider bed
The advantages of a belt
supported by means of a slider
bed are primarily that the
transported goods lay with
greater stability on the belt, and
it presents virtually no influence
on belt tracking a distinct
benefit versus a similar design
which employs carrying rollers.
With the correctly selected belt (with appropriate running side fabric)
and slider bed material it is possible to favorably influence the
coefficient of friction, running noise and the belt service life.
Attention is to be paid to the
following points:

44

 The edge of the support must be rounded and lower than the pulley
surface (h = approx. 2 mm / 0.08 in)
The heads of mechanical fasteners must be recessed below the
sliding surface
The slider bed must be precisely
aligned relative to the running
direction of the belt and it must be
leveled so that there is no tilt (this is
particularly important with slider
beds of steel sheet panels),
otherwise the belt will tend to run off
Support by carrying rollers
With long conveying distances and high
overall product loads, carrying rollers
can be used instead of a slider bed. In many cases, the roller bed reduces
friction losses. Peripheral force and drive
power requirements are proportionally
reduced.
Most commonly used are rollers made
from precision steel tubes and roller
bearings.
Rollers with a plastic sheathing can also
be used as they are resistant to
corrosion and certain chemicals. A
nonconductive synthetic cover can
produce higher static charges during operation, particularly when used in
conjunction with plastic bearings!
Carrying rollers, in virtually all cases, have a cylindrical profile. As the
conveyor belt only travels tangentially along the surface of these rollers
and does not wrap around them, these rollers may have a smaller
diameter
than that specified for the belts dmin. The specified diameter must resist
excessive deflection when the conveyor belt is under operational load.
Attention must be paid to the following points:
The distance between the carrying rollers should be less than half the
length of the transported unit loads lG, in order that the goods carried are
always on at least two rollers
Carrying rollers must be accurately fitted at right angles to the belt
running axis as skewed carrying rollers are frequently the cause of belt
tracking problems. It is sufficient if the rollers can only be adjusted from
one side, i.e. by means of slots in the supporting structure.
Pivot able carrying rollers can be installed
for the purpose of guiding belt running; in
these cases the pivot angle must be at least
45

 5. It is recommended, especially with long conveyors, that some of the

carrying rollers are adjustable.

Belt support on the return side

c. Drive concept
i. Head drive
In the case of a head-driven conveyor, the conveyor belt is said to be
pulled on the carrying side. The head
drive is preferred to the tail drive because of lower belt stress and
smaller forces imparted to the conveyor
components, i.e., pulleys and bearings.

ii. Drive units

Generally the drive comprises an electric motor, a power
transmission element (gearbox or belt) and the driving pulley.
46

Standardized three-phase squirrel-cage motors with star-delta start

are preferable. The starting is usually
smooth. The belt speed is often controlled through an electronic
frequency inverter.
The drive power ratings of fabric conveyor belts usually are relatively
small (typically between 0.5 5 kW). The
effective required motor power, required to move the fully loaded belt
along the support structure, can easily be
calculated by the CONVEY-SeleCalc program. The calculation does
not include bearing drag or belt fl exion forces
(particularly important in low temperature environment).
iii. Power transmission
The power has to be transferred from the drive to the belt. This is the
function of the driving pulley.
It transfers the drive force (peripheral force) from the pulley surface
to the belt. In driving the fl at conveyor belt, where there is no
positive engagement with the driving pulley, the power transmission
capacity is dependent upon the following factors:
Arc of contact of the belt at the driving pulley
Coefficient of friction between belt and driving pulley
Contact pressure between belt and driving pulley
d. Calculations of machine tape conveyor
where C3 =80

By assuming of V =3 m/sec

F1=
F1= 134.2*1.9 = 254.98 N
47

F2 = F1 F2 = 254.98 134.2 = 120.78 N

48

e. Tensioning devices
The required contact pressure of the conveyor belt on the driving
pulley is achieved by means of a belt tensioning device. Tensioning
force and resulting shaft load are lower if the tensioning device is
placed on the low tension (slack) side of the driving unit.
A distinction must be made between fi xed tensioning devices and
constant-force tensioning devices:
Fixed tensioning devices
Fixed tensioning devices are to be used in installations where there
is no need to compensate for variations in belt length or belt tension
during operation, further for reversing operation under full load.
Usually, fi xed tensioning devices are sufficient for fabric belt
conveying installations, because Hebraist conveyor belts are
dimensionally stable, with negligible elongation changes during startup and load changes.
A simple solution for tensioning is to use the tail pulley with a
tensioning device that runs parallel to the belt's axis or the belt's
running direction.

49

3.1.2 Project design:

Fig(3-2)

Fig(3-3)

51

Fig(3-4)

50

3.2 ELECTRONIC SYSTEM:

3.2.1 LOAD CELL CALIBRATION:
1-start siwatool fta

2-On the SIWATOOL FTA interface select the interface COM1 used on your
computer.

52

3- Click Online

4.

5-

53

6-Before calibrating, set the Service mode on (0)

54

7-Enter the Adjustment weight (e.g. "051.1") and set the Characteristic
.value range

55

8-Set parameters Min/Max weight for weighing range 0 and the

Resolution range 0 in register
.Calibration parameter 2

9-"Resolution range 1": It is the minimum change of the displayed weight. The unit is
the same as the
.Weight unit selected under the "Calibration parameter 3" tab (see below(

56

Whether the"Resolution range 1" is set to 1.0 kg the minimum change is 1

kg

10-Set parameter Weight unit in register Calibration parameter 3 and

.then click Send

57

11-Ensure the scale is empty (not loaded) and click Adjustment zero valid (3).-

12- Load the scale with the calibration weight 1 (the display may show a different
weight value and then click Adjustment weight 0 valid (4)

58

If the corresponding weight is now changed it will be according to the actual weight and
exact

.accuracy will be achieved

(Please set Service mode off (2)
.Finally you may save the calibration datas into a file
Receive all data from the SIWAREX FTA to the PC
13-save data

59

61

3.2.1PROXIMITY:

Fig(3-5)

60

3.2.2 RELAY:

Fig(3-6)

3.2.3 PNUMATIC CYLENDER

Fig(3-7)

62

3.2.4 SOLENOID VALVE

Fig(3-8)

63

3.2.5 PLC Wiring Diagram

Fig(3-9)

64

Fig(3-10)

65

Fig(3-11)

66

Chapter Four
Controller and software

67

Introduction:
In this chapter first ,we will talk about our program software flow chart
of the program , Plc program , Then HMI program and how to create
the program

4.1 Assigning parameters to the CPU

1. Open your project in SIMATIC Manager.A window, divided into
two parts, opens with the title of your project.
2. In your project, call the configuration table HW Config.
3. Double-click on the submodule "AI5/AO". The "Properties
AI5/AO2" dialog opens.
4. Disable analog output 0 by left-clicking the "Output mode" field of
the "Output " tab and select "Disabled". Close the dialog with
OK.Analog output 0 is enabled for controlling the motor power unit.
5. Double-click on the submodule "Positioning". The "Positioning
properties" dialog opens.
6. Select "Positioning with analog output". On the drive, axis and
encoder tabs, customize the properties according to your system.
7. Confirm your settings with OK.The "Positioning properties" dialog
closes.
8. Save your configuration to your project with "Station > Save and
compile".Your changes are now stored in your project.
9. When the CPU is in STOP, select "PLC > Load to module..." to
download the configuration.The data are now downloaded from the
PG to the CPU.10. Close HW Config with "Station > Close".

68

You are returned to SIMATIC Manager.

4.2 Adjustment of SIWAREX FTA (step 7) :

1. Add SIWAREX FTA to the Hardware rack from the hardware
list

2. click on SIWAREX FTA > right click on it > object

properties to adjust the address

69

3.adjust the address of inputs and outputs

4.Open the project > simatic 300 station > cpu 314-2cp > s7 program
>blocks

5. open the OB and select open> Browse

71

6.select the CD to add the SIWAREX FTA identification code

70

7. select the identification code file and the function and data blocks will
be added to the project.

8. open the OB , the identification code will be shown in the ladder

72

73

4.3 Ladder Diagram : OB1

74

75

76

77

78

4.4 Adjustment of Wincc program :

4.4.1 Component OF Win cc
Win CC Flexible Engineering System
Win CC Flexible Runtime
Win CC Flexible options

Win CC Flexible Engineering System

Win CC Flexible includes innovative engineering tool for the end to end
configuration of all Simatic HMI devices and is available in anumber of
version differentiated by price and performance thay are based on each
other and are optimally tailored to individual classes of operator panel the
larger software package always includes the configuration options of the
smaller package:
1-simatic wincc flexible Micro
Micro panel
2-simatic wincc flexible compact
Such as win cc flexiblemicro and additionally
Panels of the 70 series
Panel of the 170 series
3-SIMATIC WINCC FLEXIBLE standard
For the configuration of all somatic panels
4-simatic winccflrxible Advanced
Such as wincc flexible standard and additionally simaticn
Pcs,simotion,sinumerik panel pcs and standerd pcs

Win CC Flexible Runtim:

The runtime software is included in the somatic HMI devices and offers different HMI
functionalities and quality structures depending on the hard ware configuration of the
device for pc plat forms there are Win CC Flexible Runtime versions graded according
to the number of the power tags used
128,512 or 2048 power tags

79

Wincc flexible options:

Functional or industry-specific expansions of the engineering and runtime
software are available in the form of wincc flexible . some options already
integrated as standard functions in some HMI devices,while others are only
available above a certain class of device.

Description :
Low-priced entry-level device for basic requirements with 5.7'' STN touch
screen display featuring three levels .the device can be installed landscape
(horizontal) as

Design and functions:

The TP 177 micro is the price-optimized version of the TP 177 A and
tailored to the S7-300.
PLC . it's designed for less complex HMI tasks but thanks to its 6'' display
offers and easier
Operation than a 70 series panel . the option of installing the device
upright (portrait orientation) creates more flexibility in the machine design
The starter package is available for the TP 177 micro , which in addition to
the device includes
The configuration software Wincc flexible micro , the somatic HMI manual
collection on DVD and MPI cable

81

1.Choosing Production method screen

Ratios page, to insert the required ratios of the

three main liquids (colors) to mix them.

color library page, this page contain collection of prepared colors to

save operator time , and make the operation more easy.
1. Colors Ratios screen

80

Insert percentage of yellow color

Insert percentage of yellow color.
Insert percentage of Blue color.
2. Required Weights screen

insert the required total weight of

the mixture in Kg, which will fill in
the mixer tank.
insert the required product weight in
grams.

Insert the required number of

products.

Start the operation and start scada system.

82

3. Prepared color screen

This page gives the operator the ability of choosing a prepared

color, to save time of calculating and inserting the ratios of color.
Then go to required weights.

4. Scada System screen

83

Scada (supervisory control and data acquisition) system make a live

connection with the plc and PCs with profibus cable.

84

4.5 Flow chart of the system

4.5.1 The first stage:

Start

Choose production method

From HMI

Color Library

Ratios

Insert total weight: T_W

Insert product weight: P_W
Insert number of products :
N_P

Error MSG

YES

T_W >
Mixer
capacity

NO

85

YES
Error MSG

P_W*N
_p
>T_W

NO

Start Mixing
process

NO

Finish
Mixing

YES

END first stage

86

4.5.1 The Second stage:

Start

Starting the
motor

NO

Proximity
ON

YES

TURN MOTOR OFF

RUN THE PENUMATIC
SOLENOIDE MIXER OPEN
YES

NO

LOAD CELL
READING=
REQUIRED
WEIGHT

87

YES

TURN MOTOR ON
CLOSE PENUMATIC VALVE
SOLENOID MIXER OFF

NO

NO OF
PRODUCT
= REQUIRED
NO

END 2ND STAGE

88

Reference:

SIWAREX_FTA-en_V01
PC_Adapter_USB_e
s7300_cpu_31xc_and_cpu_31x_manual_en-US_en-US
hmi_wincc_v6_2_getting_started_en
Quality Assurance graduation project 2010
Multi Component Dosing by Weighing Control graduation project
2011
Constant water level in reservoir graduation project 2011

http://support.automation.siemens.com
https://www.automation.siemens.com/WW/forum/guests/PostS
how.aspx?PageIndex=1&PostID=110356&Language=en

89

Appendix

91

APPENDIX A
PLC SPECIFICATIONS

90

92

93

APPENDIX B
HMI TECHNICAL DATA

94

Display

5.7 inch STN display , 4 blue mode levels

Resolution

320 x 240 or 240 x 320 pixel

Control elements

Touch screen resistive analog

User memory

256 KB

Interfaces

1 x RS485

Installation cutout

198 x 142 mm (W x H)

Front panel

212 x 156 mm (W x H)

Depth

44 mm

Configuration
software

Wincc flexible compact

95

APPENDIX C
LOAD CELL GETTING STARTED

96

SIWATOOL FTA

Types of siwarex tool:

SIWAREX FTA
SIWAREX U
SIWAREX CS
SIWAREXFTC
Function
The primary task of the SIWAREX FTA consists of the precise measurement
of the current weight values in up to three measurement ranges and the
exact control of the weighing procedure. The control of the weighing
procedure is completely run from the weighing module as if in separately
constructed weighing electronics. The integration in SIMATIC enables the
progress of the weighing procedure to be influenced directly from the PLC
program however. This enables reasonable task
97

distribution: The extremely fast weighing functions are performed in the

SIWAREX module, latching and signal linking is done in the PLC
There are different automatic weighing procedures for which SIWAREX FTA
can be configured optimally by defining the corresponding parameters
Commissioning and Service with SIWATOOL FTA:
For commissioning, there is a special program SIWATOOL FTA for Windows
operating systems
The program enables commissioning of the scale without having to
understand automation technology. During service procedures, you can
analyse the processes in the scale and test them with the help of a PC.
Reading the diagnostics buffer from the SIWAREX FTA is very helpful in
analysing events
Besides complete access to all parameters, memory or print-outs of the
weighing file, the program can create weighing curves as well
SIWATOOL FTA can also be used for reading the contents of the
calibratable records from the calibratable scale memory

The following image shows the structure of the individual program

windows

98

SIWAREX

Connection areas for SIWAREX FTA

The following connection areas are found on the front as
Screw-in connector for 24 V power supply
40pin connector for load cell connection, digital input and output, RS 485
analog output, counter input
9pin (female) D-sub connector for RS 232 to PC or printer connection

99

The SIMATIC construction guidelines apply for connecting the 40 pin

connector
Flexible cables with a cross-section of 0.25 to 1.5 mm can be used.
Remove the insulation from the cable for 6 mm and install wire end sleeves

011

Load cell connections :

Sensors equipped with strain gauges and that meet the following
conditions can be connected to the SIWAREX FTA
Characteristic value 1.... 4 mV/V
Supply voltage of 10.2 V is permitted
The connection is made to the 40 pin front connector. The connection
should be
made using the cable described in chapter Accessories

010

Technical specifications of SIWAREX FTA

012