Automation of the manufacturing process of an industrial consumer

Diplomska naloga opisuje izgradnjo SCADA nadzornega sistema za industrijski proces na realnem objektu za proizvodnjo kamene volne. SCADA sistem omogoča natančen in ažuren vpogled in kontrolo nad dogajanjem v obratovalnem procesu v realnem času. Projekt je bil izpeljan s Siemensovo strojno (PLC krmilniki) in programsko opremo (STEP 7 ter WinCC). SCADA nadzorni sistem omogoča oddaljeno zbiranje procesnih stanj podatkov sistema, kar uporabniku omogoča obdelavo podatkov in ustrezno posredovanje. Nadzorni sistem spremlja stanje vhodnih in izhodnih digitalnih in analognih točk, ter posredno in neposredno vpliva na stanja le teh. Prav tako izvaja postopke in operacije po predpisanem protokolu. Hkrati pa spremlja interno diagnostiko alarmov in nadzorno – krmilnega sistema pri izbranih procesnih spremenljivkah, ter izvaja arhiviranje stanj digitalnih in analognih točk in njihov pregled. Za izdelavo SCADA sistema je bila v prvi vrsti pomembna sistemska analiza proizvodnje ter dobro poznavanje programa WinCC. Na podlagi analize delovanja proizvodnje so bili razviti posamezni programski bloki, ki so bili nato povezani v celoto. Razviti so bili tudi algoritmi za opravljanje izračunov pretokov plina, izračunov proizvodnje glede na izmeno in regulacijo. Vrednosti meritev ter dogajanje v proizvodnem procesu lahko pregledujemo in nadzorjujemo na ekranskih prikazih.This thesis describes the development of the SCADA (supervisory control and data acquisition) system for industrial process in a real object for production stone wool. The use of the SCADA system enables monitoring and control of the operating process in real time, usually at remote locations. This enables an accurate and up to date overview of the monitoring process. The SCADA system was developed with the implementation of Siemens PLC controllers and STEP 7 and WinCC software. The construction of the SCADA system requires a deep understanding and analysis of the process in consideration. This knowledge is transferred and programmed into the PLC controllers and a block diagram of the WinCC software. The hardware control loop is constantly monitoring the input and output states of digital and analog acquisition points. This enables the software control system to react and execute an operation promptly and according to the programmed protocol. At the same time it performs alarm diagnostics and stores the process variables data. In addition to the main control system, various algorithms for calculation of the gas flow and the calculation for the production output increase/decrease due to the change of work shifts were developed. The current process state and important system states are visualized live on screens on remote locations