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1、1.Intorduction Malt beer production process is divided into manufacturing, manufacturing wort, before fermentation, after fermentation, filtration sterilization, packaging, and so few procedures. Beer filling, Gland part of a packaging machine processes. The membrane filtration of beer after the pi

2、peline into the rotary Jiugang, then the valve into the bottle of wine, Gland, was bottled beer. Beer filling, Gland machine's efficiency and degree of automation direct impact on the level of beer production. China's beer industry to meet the increasing scale of production and the demand for beer

3、modern high-speed filling machinery filling the requirements of domestic beer manufacturers are actively seeking to transform the unit or the filling of beer production equipment, making it a good use Performance, advanced technology and high production efficiency and operating a safe and secure, lo

4、w maintenance costs of the modernization of beer filling machine. 2. Filling beer, Gland principle and control aircraft parts Liquid filling machine by filling principle can be divided into atmospheric filler,filling machines and vacuum pressure on the filling machine. Beer filling,Gland-filling m

5、ethod used pressure is higher than the atmospheric pressure under the filling, storage of the cylinder pressure than the pressureof the bottle, beerbottle into the liquid on pressure. Technology at home and abroad to achieve the filling line is basically: The Rotary Jiugang the rotating movement, p

6、laced in Jiugang slots on the empty bottles through the machinery will be fixed at the upper Jiugang vacuum valve to open, closed Vacuum bottles for good treatment, Bozhuan stem from operating, open the valve of the bottle filling CO2 gases, vacuum convex .Round to open the vacuum valve, the bottle

7、will air mixed with CO2 out of gas, open the valve again, the CO2 gas bottle filling, the filling valve on the pressure valve in the bottle close to back-pressure gas pressure at the open-Jiuye Pingbi into the bottle, through pneumatic or electrical control filling valve to achieve the filling of be

8、er. Today's advanced international beer filling, Gland machine control system mainly by the photoelectric switch position detection part and take the bottles with, Jiugang speed part, dominated by the PLC, touch screen and other components. Filling, Gland of the mechanical structure and PLC program

9、mable control devices, frequency stepless speed regulation, human-computer interface, and other modern means of complete automatic control technology, the combination of a mechanical and electrical integration. 3. Controlled part of the programme Many domestic beer manufacturers are now using the

10、filling, Gland of the control system of uneven degree of automation; button and all the manual switch technology have set up operations in a box on the panel, PLC controller for the majority of Japanese companies or OMRON Mitsubishi's early products, equipment chain of control, less protection setti

11、ngs, plus the beer filling the scene poor environment, humidity, such as contact with the switch contacts serious corrosion, the system's signal detection of the high failure rate, resulting in equipment control system Operation of low reliability, the normal operation of equipment, such as short-cy

12、cle phenomenon. To the actual transformation of the Dandong Yalu River Brewery Co., Ltd. of filling, Gland machine control system as an example, the transformation of methods to clarify the control of such equipment thinking and ideas, according to the scene of the actual process conditions, to pre

13、pare the operation of the PLC Procedures. For beer filling, Gland control system of the actual situation and in accordance with the actual process conditions at the scene, re-design of the equipment of the PLC control system. This transformation of the same methods and ideas can be applied to other

14、liquids and the transformation of filling equipment. 3.1 system hardware configuration Japan's Mitsubishi Corporation to use the FX2N128MRPLC use the system to replace the original 2-OMRON's C60P PLC, the original system of the PLC is due to old models, and computer on-line communications need to

15、configure special converters, the system need to increase the external I / O input points , The extension of spare parts more difficult to find. FX2N128MRPLC is an integrated 128-point I / O controller of the box, a computing speed, command rich, high-cost performance, on-line programming simple and

16、 easy extension of the advantages of the Mitsubishi FX series, features the strongest small controller . (1) by the Mitsubishi 900 series of 970 GOT human-computer touch screen system to replace the original use of the button panel display equipment and monitor the operation of operating parameters

17、. 970GOT HMI for the 16-color high-brightness significantly, through the convergence of connectivity and FX2N128MRPLC directly connected to the CPU, achieving rapid response. Has many maintenance features, such as the list-editing features, ladder monitoring (troubleshooting) function, the system mo

18、nitoring functions to find fault and maintenance of PLC Systems. (2) filling, Gland of the frequency converter in the transformation of no replacement, on-site detection signal means-testing is still used switch, switch for detecting long-term work in the humidity of the great occasions, the choice

19、 of capacitive proximity switches, according to PLC I / O terminal of the connection mode, select the type of close PNP switch, the control system of Figure 1. 3.2 Systems Programming PLC controller programming focus and the core is around Jiugang the rotation speed control and Jiugang on 60 bottl

20、es of detecting the location of the displaced, broken bottles, empty bottles at the location of testing and related displacement filling Such as control valves. The bottles displacement of testing procedures, using a Mitsubishi PLC in the left command.Figure 1 control system structure diagram . Bot

21、tles displacement of detection, using the left-PLC command, which commands the whole of one of the core control procedures, the main electrical switch detection and bottles at the bottle simultaneously detect mobile, the main motor to every week, just to the corresponding Jiugang Have a bottle of, P

22、LC unit within the internal correspondence that 60 bottles of the unit for the M500 ~ M559, the number of units by the first letter K is set to K60, with each change in a second letter K is set to K1, M50 Reaction of the empty bottles in the short position, and detect the location of the motor speed

23、 to go on the frequency shift in the corresponding unit within the built-in "1" or "0", control valves and the corresponding mixing caps The motor stopped and opened. Continuous detection system in place after the 90 empty bottles, stop stirring caps the motor running, testing the number of bottles

24、in accordance with the user's requirements can be arbitrary. A bottle of detection. Rotary Jiugang through pressure to back pressure with the bottle of liquor in the process of empty bottles in the back-pressure, because the bottle itself may crack and other reasons leading to a sudden burst bottle

25、s, which need to detect the location of unexploded bottle bottle, in this bottle - The position opened purge solenoid valves, compressed air out, broken bottles at the bottle-blowing from the position in a row after the purge and several bottles of the electromagnetic valve open jet, a high-pressure

26、 spray Shuizhu, in the break Bottle position around a few bottles of spray bottles in a row. Detection of broken bottles and bottle-detection switch simultaneously detect movement of breaking bottles, to the main motor of each week, precisely corresponding Jiugang passed a bottle of, PLC unit withi

27、n the internal correspondence that 20 broken bottles at the unit for the M600 ~ M619, unit With the number of the first letter K is set to K20, with each change in a second letter K is set to K1, M52 response to the location of the broken bottles and detected the location of the motor speed to the f

28、requency shift continue, In the corresponding unit within the built-in "1" or "0", control and the corresponding jet purge solenoid valve opened and stopped. Continuous Spray and purge solenoid valve open to listen, time stopped in accordance with technological requirements can be arbitrary. System

29、 security is to control access to the caps simultaneously tracking, not only accurately detect the electrical switching speed detection, the broken bottles into the bottle and detection switch detection switch three conditions. 970GOT human-computer touch-screen terminals operated by the software c

30、ompany's Mitsubishi GT WORKS package, which is a GT Designer with the entire GOT9000 series of graphics software packages. The package is simple, prior to a personal computer simulation on the configuration and debug, after the man-machine operators to download terminals. At the same time, because t

31、he man-machine interface and a touch-screen role, will set common switch on thescreen to facilitate the operation. And also to increase the number of features, such as setting alarm information. 4. After transformation control system System at the normal operation of the machine for automatic cont

32、rol, in accordance with bottles into and out of the bottle for lack or slow pace set by running into the bottle stall bottles, no less than a bottle cap, automatic washing bottles burst, filling automatic back-pressure position , Covered under the system automatically lose covered a stop and safety

33、protection, such as the coordination of action interlock. All the original button after the operation of the touch screen on. 5. Detection of the state control system monitoring Detection switch into the bottle and break bottles detection switch bottles of pressure bytesting each part of the small

34、 metal plates above the location of a photoelectric pulse output, a further PLC acquisition, as each bottle of the pressure above the small metal plates is the location of activities , In the machine running after some time, some pressure above the small bottles of iron tablets and detection switch

35、in the location of displacement, resulting in detection switch mistaken judgement, if not for the judgement of bottles of bottles, bottle explosion Lou Jian, misuse, such as the seizure of output errors So that the PLC have mistaken action, such as a back-pressure, unexploded bottle blowing, washing

36、, stirring cap control system malfunction, such as failure phenomenon. Before the transformation of the daily production process, encountered this phenomenon, the operatives could only switch to the various functional or manual control buttons reach the stall so that the equipment work in the absen

37、ce of monitoring state, the machine lost control function. Caused a lot of production of raw materials such as gas, water, wine waste. Only in the production of intermittent, can be fitter and maintenance electrician in accordance with the detection of small switch on the light-emitting diodes and a

38、nti-displacement by adjusting the distance only 5 ~ 8 mm detection switch installation location, and switch to fix detection of small metal plates Gap. This means of detection is very backward, after adjustment reaction to the results, timely response can not be adjusted results. In view of this te

39、sting situation, after the transformation of the filling, Gland control system configuration, this part of a new detection and integration in human-computer touch screen, complete bottle of detection. In human-computer touch screen interface on the page display, respectively, at customs, such as el

40、ectromagnetic motor mixing valve switch state are in different colors to show, very intuitive. Increase the system's functions is to ensure the irrigation of the machine-Gland normal operation of automated control system specifically designed to. 6 Concluding remarks After the transformation of t

41、he control system will greatly simplify the complicated mechanical structure, the running and control of inspection, the degree of automation systems meet the design requirements, greatly reducing the operational strength of the labor so that the shrub-like beer output than in the past Raising more

42、than 30 percent, greatly reduce the failure rate. Embodies the modern equipment of automatic control technology. In the digestion and absorption of today's industrial control on the basis of advanced technology innovation, development of domestic technology from the most advanced filling control sys

43、tem. 啤酒灌裝、壓蓋機(jī) PLC 控制系統(tǒng) 1. 引言 啤酒生產(chǎn)過程分為麥芽制造、麥芽汁制造、前發(fā)酵、后發(fā)酵、過濾滅菌、包 裝等幾道工序。啤酒灌裝、壓蓋機(jī)部分屬于包裝工序。啤酒經(jīng)膜過濾后由管路送 入回轉(zhuǎn)酒缸，再經(jīng)酒閥進(jìn)入瓶子中，壓蓋后獲得瓶裝啤酒。啤酒灌裝、壓蓋機(jī)的 工作效率和自動(dòng)化程度的高低直接影響啤酒的日產(chǎn)量。 為了滿足我國啤酒行業(yè)日益擴(kuò)大生產(chǎn)規(guī)模的需求和啤酒現(xiàn)代化灌裝機(jī)械高 速灌裝的要求，國內(nèi)各啤酒生產(chǎn)廠家都在積極尋求或改造本單位的啤酒灌裝生產(chǎn) 設(shè)備，使其成為具有良好的使用性能，先進(jìn)的技術(shù)水平及高生產(chǎn)效率、運(yùn)行穩(wěn)妥 可靠、維護(hù)成本低的啤酒現(xiàn)代化灌裝機(jī)。 2. 啤酒灌裝、壓蓋機(jī)

44、工作原理和控制部分構(gòu)成 液體灌裝機(jī)按灌裝原理可分為常壓灌裝機(jī)、壓力灌裝機(jī)和真空灌裝機(jī)。啤酒 灌裝、壓蓋機(jī)采用壓力灌裝方法，是在高于大氣壓力下進(jìn)行灌裝，貯液缸內(nèi)的壓 力高于瓶中的壓力，啤酒液體靠壓差流入瓶內(nèi)。 目前國內(nèi)外實(shí)現(xiàn)灌裝工藝路線基本上是：利用回轉(zhuǎn)酒缸產(chǎn)生的旋轉(zhuǎn)運(yùn)動(dòng)，使 安放在酒缸槽位上的空瓶通過機(jī)械機(jī)構(gòu)將固定在酒缸上部的欲抽真空閥打開，對 已封好的瓶子進(jìn)行抽真空處理，撥轉(zhuǎn)外操作閥桿，打開氣閥，對瓶內(nèi)充填 CO2 氣體，抽真空凸輪繼續(xù)打開真空閥，將瓶內(nèi)空氣與 CO2 混合氣體抽出，氣閥再次 打開，對瓶內(nèi)充填 CO2 氣體，灌裝閥內(nèi)的液閥在瓶內(nèi)壓力接近背壓氣體壓力時(shí)打 開，酒液順瓶壁注入

45、瓶內(nèi)，通過氣動(dòng)或電動(dòng)控制灌裝閥實(shí)現(xiàn)啤酒的灌裝。 當(dāng)今國際先進(jìn)的啤酒灌裝、壓蓋機(jī)的控制系統(tǒng)主要由光電開關(guān)位置檢測部 分、走瓶帶、酒缸轉(zhuǎn)速的變頻調(diào)速部分、主控由可編程控制器、觸摸屏等組成。 灌裝、壓蓋機(jī)的機(jī)械結(jié)構(gòu)裝置與 PLC 可編程控制、變頻無級調(diào)速、人機(jī)界面等現(xiàn) 代自動(dòng)控制技術(shù)手段完整的結(jié)合，形成機(jī)電一體化。 3. 控制部分改造方案 國內(nèi)很多啤酒廠家現(xiàn)使用的灌裝、壓蓋機(jī)的控制系統(tǒng)的自動(dòng)化程度參差不 齊；所有手動(dòng)按鈕和工藝開關(guān)都設(shè)置在一個(gè)操作箱的面板上，PLC控制器大都為 日本OMRON公司或三菱公司的早期產(chǎn)品，設(shè)備連鎖控制、保護(hù)設(shè)置少，加之啤酒 灌裝的現(xiàn)場環(huán)境惡劣，潮濕度大，使開關(guān)等接

46、觸觸點(diǎn)銹蝕嚴(yán)重，系統(tǒng)的信號檢測 部分故障率較高，造成設(shè)備控制系統(tǒng)運(yùn)行的可靠性低，設(shè)備正常運(yùn)行周期短等現(xiàn) 象。 以實(shí)際改造的丹東鴨綠江啤酒有限公司的灌裝、壓蓋機(jī)的控制系統(tǒng)為例，介 紹改造方法，闡明改造這類設(shè)備的控制思想和思路；根據(jù)現(xiàn)場的實(shí)際工藝條件， 重新編寫了 PLC的運(yùn)行程序。針對啤酒灌裝、壓蓋機(jī)控制系統(tǒng)的實(shí)際狀況，并根 據(jù)現(xiàn)場的實(shí)際工藝條件，重新設(shè)計(jì)了設(shè)備的PLC控制系統(tǒng)。這種改造方法和思路 同樣可以應(yīng)用與其他液體介質(zhì)灌裝設(shè)備的改造。 3.1 系統(tǒng)硬件配置 使用日本三菱公司的FX2N128MRPLC替換原系統(tǒng)使用的2臺OMRON公司的 C60PPLC，原系統(tǒng)的PLC由于是老型號產(chǎn)品，

47、和計(jì)算機(jī)聯(lián)機(jī)需要配置特殊的通訊 轉(zhuǎn)換器，系統(tǒng)需要增加外部I/O輸入點(diǎn)時(shí)，擴(kuò)展模塊備件較難尋。FX2N128MRPLC 是集成128點(diǎn)I/O的箱體式控制器，具有運(yùn)算速度快，指令豐富、性能價(jià)格比高、 聯(lián)機(jī)編程簡單、擴(kuò)展方便等優(yōu)點(diǎn)，是三菱FX系列中功能最強(qiáng)的小型控制器。 (1) 采用三菱公司的900系列的97OGOT人機(jī)觸摸屏替換原系統(tǒng)使用的面板 按鈕并監(jiān)控顯示設(shè)備的運(yùn)行工作參數(shù)。970GOT HMI為高亮度的16色顯，通過匯 流連接和FX2N128MRPLC的CPU直接連接，實(shí)現(xiàn)快速回應(yīng)。具有許多維護(hù)功能， 如列表式編輯功能、梯形圖監(jiān)控(故障查找)功能、系統(tǒng)監(jiān)控功能等用來查找故障 和維護(hù)PLC系

48、統(tǒng)。 (2) 灌裝、壓蓋機(jī)的變頻器在改造中沒有更換，現(xiàn)場檢測信號的手段仍然采 用開關(guān)式檢測，因檢測開關(guān)長期工作在濕度很大的場合，因此選擇電容式的接近 開關(guān)，根據(jù)PLC I/O端子的接線方式，選擇PNP型的接近開關(guān)。 3.2. 系統(tǒng)程序設(shè)計(jì) PLC 控制器的程序設(shè)計(jì)重點(diǎn)和核心是圍繞著酒缸的旋轉(zhuǎn)速度控制和酒缸上 60 個(gè)瓶位相關(guān)位置的檢測移位、破瓶、空瓶瓶位相關(guān)位置的檢測移位和相關(guān)灌 裝閥等的控制。其中的瓶位移位檢測程序中，采用了三菱 PLC 位左移指令。 瓶位移位檢測，采用 PLC 位左移指令，這條指令是整個(gè)子控制程序的核心之 一，主電機(jī)和瓶位檢測開關(guān)同步檢測移動(dòng)的酒瓶，主電機(jī)每轉(zhuǎn)一周，

49、正好對應(yīng)酒 缸轉(zhuǎn)過一個(gè)瓶位，PLC內(nèi)部單元內(nèi)對應(yīng)這60個(gè)瓶位的單元為M500~M559,單元個(gè) 數(shù)用第一個(gè)字母K設(shè)置為K60，每次變化一位用第二個(gè)字母K設(shè)置為K1，M50反 應(yīng)了瓶位的空、缺位置，并將檢測到的這個(gè)位置以電機(jī)轉(zhuǎn)速的頻率移位下去，在 內(nèi)部相應(yīng)的 單元內(nèi)置"1"或"0"，控制相應(yīng)的閥門和攪拌瓶蓋的電機(jī)的開與停。 系統(tǒng)在連續(xù)檢測90 個(gè)空瓶位后,停止攪拌瓶蓋的電機(jī)的運(yùn)行,檢測瓶位的個(gè)數(shù)可 以根據(jù)用戶的要求任意設(shè)定。 出瓶位檢測。回轉(zhuǎn)酒缸通過壓力往瓶內(nèi)背壓裝酒的過程中，空瓶在背壓后, 可能由于瓶子本身裂紋等原因?qū)е峦蝗槐?這就需要檢測出爆瓶瓶子的位置, 在這個(gè)瓶位的位置進(jìn)行打開吹掃電

50、磁閥,噴出壓縮空氣,將瓶位上的碎瓶片吹離 位置,在連續(xù)吹掃幾個(gè)瓶位后,在打開噴射電磁閥,噴射出高壓水注,在對破瓶位 置周圍瓶位連續(xù)噴射幾個(gè)瓶位。 破瓶檢測和瓶位檢測開關(guān)同步檢測移動(dòng)的破瓶，主電機(jī)每轉(zhuǎn)一周，正好對應(yīng) 酒缸轉(zhuǎn)過一個(gè)瓶位，PLC內(nèi)部單元內(nèi)對應(yīng)這20個(gè)破瓶位的單元為M600~M619,單 元個(gè)數(shù)用第一個(gè)字母K設(shè)置為K20,每次變化一位用第二個(gè)字母K設(shè)置為KI, M52 反應(yīng)了破瓶的位置，并將檢測到的這個(gè)位置以電機(jī)轉(zhuǎn)速的頻率移位下去，在內(nèi)部 相應(yīng)的 單元內(nèi)置"1"或"0"，控制相應(yīng)的噴射和吹掃電磁閥開與停。連續(xù)噴射和 吹掃電磁閥的開聽、停時(shí)間可以根據(jù)工藝要求任意設(shè)定。 系統(tǒng)自動(dòng)化運(yùn)行

51、可靠的保障就是控制進(jìn)出瓶蓋的同步跟蹤，既準(zhǔn)確檢測電機(jī) 轉(zhuǎn)速檢測開關(guān)、破瓶檢測開關(guān)和進(jìn)瓶檢測開關(guān)三個(gè)條件。 970GOT人機(jī)觸摸屏操作終端機(jī)的軟件采用三菱公司的GT WORKS軟件包，其 中GT Designer是一個(gè)用與整個(gè)GOT9000系列的繪圖套裝軟件。該軟件包操作簡 單，事先可在個(gè)人計(jì)算機(jī)上組態(tài)并仿真調(diào)試，完畢后下載至人機(jī)操作終端機(jī)。同 時(shí)，因?yàn)槿藱C(jī)界面又具有觸摸屏的作用，將常用的開關(guān)設(shè)在顯示屏上，方便操作。 還可并以增加一些功能，如設(shè)置報(bào)警信息等。 4．改造后控制系統(tǒng)功能 系統(tǒng)正常運(yùn)行時(shí)，機(jī)器為自動(dòng)控制，根據(jù)進(jìn)出瓶帶上瓶的滿缺，按設(shè)定速度 或慢速運(yùn)行，進(jìn)瓶檔瓶，無瓶不下蓋，爆瓶自

52、動(dòng)沖洗，灌裝位置自動(dòng)背壓，下蓋 輸蓋系統(tǒng)的自動(dòng)開停和安全保護(hù)等動(dòng)作的協(xié)調(diào)聯(lián)鎖。原來所有按鈕的操作改造后 都在觸摸屏上進(jìn)行。 5．控制系統(tǒng)檢測狀態(tài)的監(jiān)控功能 進(jìn)瓶檢測開關(guān)和破瓶檢測開關(guān)通過檢測每個(gè)壓瓶部分上面的小鐵片的位置， 產(chǎn)生光電脈沖輸出，再有 PLC 采集，由于每個(gè)壓瓶部分上面的小鐵片的位置是活 動(dòng)的，在機(jī)器運(yùn)行一段時(shí)間后，壓瓶部分上面的小鐵片和檢測開關(guān)的位置發(fā)生位 移，造成檢測開關(guān)誤判斷，如沒瓶判斷為有瓶，爆瓶漏檢、誤檢等造成輸出失誤， 使 PLC 產(chǎn)生誤動(dòng)作，造成如背壓、爆瓶吹、洗、瓶蓋攪拌系統(tǒng)控制失靈等故障現(xiàn) 象。 在改造前的日常生產(chǎn)過程中，碰到這種現(xiàn)象時(shí)，操作工只能將各個(gè)功能

53、開關(guān) 或按扭打到手動(dòng)控制檔位，使機(jī)器設(shè)備工作在無監(jiān)控狀態(tài)下，機(jī)器失去自動(dòng)控制 功能。造成了很大的生產(chǎn)原料如氣、水、酒的浪費(fèi)。只能在生產(chǎn)的間歇，才能由 維修鉗工和電工根據(jù)檢測開關(guān)上的小發(fā)光二極管的亮和滅通過調(diào)整位移距離只 有 5~8mm 的檢測開關(guān)的安裝位置，來修正檢測開關(guān)和小鐵片的間隙。這種檢測手 段非常落后，調(diào)整后的效果反應(yīng)致后，不能及時(shí)反應(yīng)調(diào)整結(jié)果。 針對這種檢測狀況，結(jié)合改造后的灌裝、壓蓋機(jī)控制系統(tǒng)的配置，新增了這 部分檢測功能，并集成在人機(jī)觸摸屏中，完成瓶位檢測。 在人機(jī)觸摸屏的界面分頁顯示屏上，可以分別時(shí)關(guān)、攪拌電機(jī)等電磁閥的開 關(guān)狀態(tài)都以不同顏色來顯示，非常直觀。 增加這套系統(tǒng)功能的是為保證灌狀壓蓋機(jī)的自動(dòng)化控制系統(tǒng)正常運(yùn)行而專 門設(shè)計(jì)的。 6．結(jié)束語 改造后的控制系統(tǒng)大大地簡化了復(fù)雜的機(jī)械結(jié)構(gòu)，經(jīng)現(xiàn)場運(yùn)行情況和控制效 果檢驗(yàn)，系統(tǒng)的自動(dòng)化程度達(dá)到了設(shè)計(jì)要求，大大減少了操作人員的勞動(dòng)強(qiáng)度， 使啤酒灌狀的日產(chǎn)量比過去提高 30%以上，故障率大大減低。體現(xiàn)了現(xiàn)代設(shè)備的 自動(dòng)控制技術(shù)。是在消化、吸收當(dāng)今工業(yè)控制的先進(jìn)技術(shù)的基礎(chǔ)上加以創(chuàng)新、研 制而成的目前國內(nèi)技術(shù)最先進(jìn)的灌裝控制系統(tǒng)。