• Nyzhnodniprovska Street, 8
    Ukraine, 69091 Zaporizhzhia
  • +38(061) 270-78-17
    info@etm.io
27
Feb 20
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AUTOMATED CONTROL SYSTEM OF A SHIFT TASK COMMUNICATING

Automated control system of a shift task communicating (64-bit code) for Welding shop of PJSC ZAZ is intended to exchange the data between the plant database and automated control system of a shift task;

The system provides:

  • automatic communicating of a shift task out of the plant database into the current Welding shop Production management system;
  • automatic communicating of a 64-bit response code from Welding shop Production management system to the plant database and to dispatcher’s workstation;
  • long term archive storage of a shift task parameters.
  • Client PJSC "ZAZ"
  • Skills Automation
  • Website https://www.avtozaz.com
  • Share
  • Project Starting Date

    15.06.2012

  • Project End

    23.06.2012

  • Category

    Automotive

SCOPE OF WORK DONE:

  • The cabinet for a server workstation and network equipment was installed to arrange the data exchange between Welding shop Production management system and the plant database.
  • To perform the monitoring and control over the Welding shop Production management system from the dispatcher’s display, the workstation with a display for decoded visualization of done, upcoming and planned tasks was installed.
  • The server and dispatcher’s workstation are PCs with virtual technology OS.
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THE SYSTEM WORKS LIKE THIS:

  • The plant database issues a task and sends it to Buffer 1 for readout.
  • Buffers 1 and 2 are “.csv” text files.
  • SCADA SIMATIC WinCC system receives a new shift task from Buffer 1 and sends it to the dispatcher’s workstation.
  • The task is displayed decoded at the dispatcher’s workstation and is enqueued for checking. Dispatcher checks the received tasks and pushes the button to confirm them.
  • Confirmed tasks go to Welding line control system via OPC-server for fulfillment.
  • After the task is fulfilled, Welding line control system amends 64-bit task code with the response data, that contains fulfillment status and diagnostic data.
  • Response 64-bit code goes to WinCC server via OPC-server. Then the information is sent to the workstation displaying operations’ fulfillment status to the dispatcher.
  • As well, Response 64-bit code is communicated by WinCC-server to Buffer 2. The plant database can gain the response 64-bit code data from this file.
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27
Feb 20
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AUTOMATION OF BODY TRANSFER SYSTEM AT THE BODY FINAL ACCEPTANCE LINE

Body transport conveys different bodies from the rotating table of a skid transport system on the delivered lift empty skid of a final acceptance line.

Performed operations:

  • body feed to the skid transport;
  • manipulator descending and body clamping;
  • manipulator raise;
  • horizontal motion of the manipulator from the body pick to the body drop areas – lift table with delivered skid at a final acceptance line;
  • lowering of a manipulator with a body on the skid, unclamping and manipulator raise;
  • body descending on skid, clamped on the lift table for further transfer on the final acceptance line
  • manipulator return to home position.
  • Client PJSC "ZAZ"
  • Skills Automation
  • Website https://www.avtozaz.com
  • Share
  • Project Starting Date

    10.07.2012

  • Project End

    07.08.2012

  • Category

    Automotive

SCOPE OF WORK DONE:

ETM created a control system, ensuring a safe body transport operation in a set mode.

  • In automatic mode: the system is controlled by PLC; selection and performance of every next step is defined by PLC.
  • In semi-automatic (adjustment) mode: the system is controlled by PLC, action selection (next step of an operating sycle) – if this step is allowed to the transport after operator’s command.
  • In manual (emergency) mode: the manipulator operates under the direct operator’s supervision, PLC is off the control circuit.
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Manual (emergency) operation mode performs the operator’s command when emergency signals are on, when transport protection circuits and adjacent lines signals are produced. Manual (emergency) mode is selected by an emergency operation switch.

  • To perform actions (different steps of an operation cycle) of the transport, the skid transport system, body transfer line control system and final acceptance line control system exchange signals.
  • To define the authorization signal, the signals of sensors and end-switches of the body transfer line are correlated with the signals of the skid transport system of the final acceptance line.
  • Actions of a body transport are correlated with transfer line signals and final acceptance line.
  • Preventing conflicting commands (e.g. simultaneous motion in opposing directions) by mechanical mutual block of buttons or switches installation.
  • ETM created a real-time control system for instant critical equipment failure detection – motors failure, belt tension control, current step-up, which means motor start without a start command etc. and further automatic reaction of a transport control system protection circuit and simultaneous signal sending to adjacent control system (body transfer line, final acceptance line).
  • Descending cycle type switch was made depending on the body availability on a skid. Descending cycle type switch must ensure the precise identification of the descending type. Formed descending cycle type signal is sent to the transport control system.
  • Optic sensor is used for the final acceptance line software to detect the body availability on a
  • End-switch is used in the final acceptance line software to define the body type.
05
Jun 19
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The control system of sand-throwing machine PN-40

In a case of batch production, large-scale and mass production of castings to improve the quality and increase the productivity of labor machine methods of making molds are used. At the same time, along with molding machines in cast shops sand-throwing machines are used.

The sand-throwing machine is throwing molding machine, which throws a moldable mixture in the flask at the same time filling it and making compaction of the mixture. Usually, sand-throwing machine are used to stuff medium and large forms, since the size is too small flask obtained significant loss of molding sand, and since the size of the flask is too small there it can result significant loss of molding sand, because of missed sand while stuffing near the edge of the flask. The following types of sand-throwing machines are:

  • stationary two-armed;
  • movable console;
  • bridge;
  • outboard
  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share
  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Automotive

The sand-throwing machine PN-40 is a bridge type sand-throwing machine designed for stuffing large forms molds. The sand-throwing machine design is similar to the design of the bridge crane, where instead of lifting mechanism the impeller head is installed, which is a rapidly rotating rotor with several paddles. These blades and throw out of the impeller head «packages» of moldable mixture at high speed straight down into the flask. For feeding the mixture into an impeller head there is a special system of two belt conveyors (one of which is fixed and the other moves). The productivity sand-throwing machine – 40 m3/h, the served area – 3,0h3,0 m, the number of rotation of the rotor impeller heads per minute – 1470.

LLC “Elektrotekhmash” developed control system has the following functions:

  • control of mechanisms of movement of the bridge and the trolley;
  • control of the drive of rotation of the impeller head;
  • control of the reclaimer;
  • padding of shapes of molds and rods in the automatic mode.
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05
Jun 19
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Mobile system for remote monitoring and control

Today, an important criterion of any enterprise is the ability to provide information on the results of its work. The ability to obtain this information should not be limited by the territorial location of the user and the presence of computer at the time of receiving the information. It is important that the data should be protected against unauthorized access.

The widespread use of compact devices (phones, tablets), running on the Android operating system, makes it possible to affirm that you can create applications that provide users with obtaining information on this platform.

This mobile system has been developed to monitor the production at the oil-extraction plant. Providing remote monitoring of the arrival of raw materials to the main technological line, as well as receiving information on the output of finished products.

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share
  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Automotive

Mobile system for remote monitoring and control used to monitor and control the production process and parameters. The operator’s automated workplace is the link between the manufacture (in which there is a local ETHERNET network) and a smartphone (communication is provided over the Internet WAN). It is the operator’s workstation where data files in the system are generated. To open the data file the mobile application Informer developed by LLC “Elektrotekhmash” is used.

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The system provides:

  • monitoring of process equipment;
  • displaying numerical indications of the number of raw materials arriving into the production, and produced finished products.

Controlled items are:

  • the status of all nodes participating in the process and the relationship between them;
  • options chosen by the customer, based on which the company reports on progress will be formed.

On request of user the following reports can be generated by the application:

  • report for the day;
  • report for the week;
  • report for the month.
05
Jun 19
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Remote control system of cylinder oxygen filling on the water ramps

Nowadays oxygen has wide application in metallurgy, chemical, petrochemical, pulp and paper, food industries, power engineering, medicine and agriculture. It is obtained from air by cryogenic distillation and water electrolysis.

Oxygen is transported in cylinders. To fill them up gas is supplied through the pipeline to the filling manifold—ramp, to which the cylinders are attached. Filling manifold consists of two identical branches, branch connection node and racks. There are valves for connecting the cylinders on each branch and one end valve for pulling the gas from the branch. The connection node of the branches consists of two valves (gas flow into the branches), pressure gauge and safety valve.

Filling ramps are of two types:

  • 2 x 5 — fill up five cylinders in every branch of the ramp (used for oxygen plants, proizvoditlnost to 30 m3/h)
  • 2 x 10 — to each branch of the ramp are attached ten cylinders.

When filling up a large number of cylinders, up to 20 cylinderscan be attached to each branch.

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share
  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

Remote control system of cylinder oxygen filling on the water ramps

The remote control system of cylinder oxygen filling on the water ramps can transmit information about the status of the process to the computer located at a significant distance. The resulting information is presented in the form of graphs and tables with their subsequent archiving.

The remote control system of cylinder oxygen filling on the water ramps provides:

  • non-stop operation;
  • connection with remote nodes via GSM;
  • polling the diagnosed equipment;
  • processing of of received signals and the received information;
  • the possibility of accumulation of statistical data on the process;
  • automatic making of reports.
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05
Jun 19
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Automatic control system of the vacuum-ammonium drying section

To form a ceramic shell the refractory coating is subjected to air, air-ammonia and ammonium-vacuum drying. The practice shows, the drying duration depends on the number of applied layers and model complexity and differs significantly for different methods. Thus, it is possible to dry coating on air for 4-10 hours, air-ammonia drying lasts for 1-3.5 hours. The most rapid way is the ammonium-vacuum drying which takes from 15 to 30 minutes.

At the end of the process the model composition is removed from shells by melting of different methods (in hot water; in the molten model composition of the same brand, with hot air) at temperatures of 96-200оС.

To monitor the progress of the drying process and management of the unit the ACS is created.

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share
  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

Installation of vacuum- ammonia drying is intended to dry the ceramic coating forms on the melted models using a vacuum and ammonia.

To display information about the progress of the process and control the plant an automated system was developed, with number of basic features:

  • Providing two modes of operation of the unit – automatic and adjusting:
    • while working in adjustment mode it is carried out step by step management unit with the ability to change the time of all the necessary exposures;
    • while working in automatic mode the control program is automatically processed with all the timeslots to the end of the cycle.
  • With the help of signal reinforcement it shows step by step all the switching mechanisms.
  • All data are saved in nonvolatile memory.
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05
Jun 19
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Automatic control system of a cell-type cooling tower

The cooling tower is a device for cooling a large amount of water by directed air flow. Cooling towers are used in water recycling systems for cooling heat exchangers.

In mechanical-draft cooling tower the cooling process is going on due to evaporation of a part of water when its runoff by a cooling tower filler along which in the opposite direction of the water movement the flow of air is supplied. Evaporation of 1% water leads to decrease in the temperature of the remaining water mass to 5,48оС.

Automatic control system of a cell-type cooling tower is intended for the fan control using frequency converters.

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share
  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

Automatic control system of a cell-type cooling tower is intended for the fan control using frequency converters. Its use enables the control of the cooling process, which is achieved by precise regulation of the fan speed and thus the cooling water process. Additionally, the system monitors and alerts the operator of any malfunctions in the production equipment.

The system provides:

  • stable predetermined cooling water temperature;
  • safe operation of the cooling tower.

The economic effect from the implementation of ACS is achieved by reducing the annual electricity consumption more than 30%.

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05
Jun 19
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SCADA-system of aeration device

Transloading of bulk materials is the most common operation in processing of mineral raw materials. The process of moving of bulk materials is accompanied by significant dust emissions. The agglomerate transloading process results the biggest emission of dust. Additionally, you must clear air from harmful substances produced during the solid-fuel combustion.

To reduce dust emission during such production aeration devices are widely used. Their usage allows not only to protect the environment from industrial waste, but also to get economic benefits by returning to the production cycle of dustlike raw material.

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share
  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

Water purification technology

The aeration device is a complex of technical and program means for air purification of harmful substances appearing during the combustion of solid fuels in furnaces. This hardware-technical complex consists of:

  • the filter, providing air cleaning;
  • the exhauster, necessary for extraction of air from the furnace;
  • the lube oil console , which provides the necessary equipment operations;
  • compressor, creates the necessary air pressure for the impulsive operated bag filter cleaning valves;
  • spark-arrester cyclone;
  • transport system of outloading of dust from the filter hoppers;
  • two united dust bunkers.

The filter is controlled by Siemens S7-1215C controller. To visualize the filter operation, local control and setting necessary settings the operator panel TP700 Comfort is used. Connection between the controller and the operator is carried out via the Ethernet line. The management of all other parts of the aeration device is carried out by the Siemens S7-315-2 controller.

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Developed SCADA-system provides a complete visualization of the technical process and all components of the aeration device and gives the possibility to manage its actuating mechanisms. In this system involved 708 data signals and control signals, among which:

  • 54 analog signals;
  • 654 discrete signals.
05
Jun 19
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SCADA-system the chemical water treatment line

Production of semiconductor silicon requires purified water with low content of suspended solids, metal and acid ions, gases, organic substances and microorganisms.

Tasks of water treatment for production are:

  • disinfection of water (purification from microorganisms);
  • mechanical impurities filteration;
  • clarification (removal of iron and manganese);
  • desalination;
  • degassing (oxygen removal).

Analysis of water used on semiconductor plants is generally done according to following criteria:

  • electrical resistivity (conductivity);
  • oxidation
  • silica content

The main treatment technologies methods are distillation and ion-exchange resin transmission. After one or two stages of distillation water electrical resistivity reaches 0.3-0.5 MO*sm, and on the output of ion exchange units – 1-20 MOm*sm.

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share
  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Metallurgy

Even a product water is a solution containing such contaminants as dissolved acid, base, salts, oxides the amount of which you can count by means of the resistivity. Measurement of the resistivity is carried out by using two electrodes placed in the vessel of regular geometric shape. Measurements are made on an alternating current in order to exclude the dissolution and deposition of impurities on these electrodes.

Oxidability of water is determined by the amount of oxygen required for complete dissolution of contained organic substances. After adding a strong oxidant into a product water, they determine the content of oxides in water or amount of spent oxidant. The oxidation of water is calculated according to the results..

Water contamination with silicic acid occurs in the process of its purification or during transportation. Evaluation of the content of silicic is made by means of the colorimetric method – transforming silicic acid to silicomolybdic acid and comparing the color intensity of the test solution with the standard.

Water purification technology

At the first stage of cleaning the raw water passes through the bacteriological cleaning with sodium hypochlorite. Sodium hypochlorite, forming sodium cations and anions of hypochlorous acid when dissolved in water, today is one of the best means of showing strong antibacterial activity.

Disinfected water is cleaned through the mechanical filters and the storage tank, and then by adding sodium metabisulfite removal of chloramine is made.

Then water is degassed and sent to the mixed bed filters containing ion exchange resins. Thus receiving the highest degree of purification. Cleanability of resins in the process of saturation with anions and cations is reduced, which leads to the periodic need to regenerate. Regeneration is carried out with weak solutions of acids (cation exchange resins) and alkali (anion exchange resin), and after it the resins column is rinsed with water.

Chemical water treatment is a complicated process that requires monitoring and control of technological parameters of the equipment. In addition, registration and storing of indicators of preparation process is required. Chemical treatment system is equipped with the following sensors with analog outputs:

  • flow sensors;
  • pressure sensors;
  • sensors for measuring the resistivity (conductivity) of water;
  • water temperature sensors;
  • level sensors in vessels.

Also, the system has the valve position sensors with analog and digital output signals.

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Advantages of SCADA-system:

  • increasing the efficiency of management of line of chemical treatment of water in general;
  • displaying the progress of technological water treatment process;
  • displaying, recording and storage of process parameters;
  • control of indicator values and alarms in case of deviation from the values of specified limits;
  • possibility of remote control of water treatment process from the automated working station;
  • prompts to the operator in making decisions in different situations;
  • recording of operator’s actions.
05
Jun 19
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Automated control system of railway wheel rim hardness measurement node

Railway wheels are in the list of the most critical elements of the rolling stock of the rail transport. While train movement the wheels are affected by static, cyclic and dynamic load, and in local areas (while slowing down) – by cyclic influences of high temperature. Every wheel element has a rapid time-varying system of compressive and tensile stresses. The voltage wheel–rail contact lead to breakages, most of which can be classified as rolling surface wair, thermal and contact–fatigue defects, brittle metal fracture.

The most important railway wheels quality parameter is hardness. Hardness requirements for wheels are established by national and international standards.

Automated control system of railway wheel rim hardness measurement node was created to fulfill the railroad wheels quality requirements, and is based on EMKO hardness tester.

  • Client JSC "Zaporizhstal"
  • Skills Automation
  • Website https://www.zaporizhstal.com
  • Share
  • Project Starting Date

    12.12.2017

  • Project End

    20.12.2017

  • Category

    Automotive

The efficiency of work on the railway transport is largely depends on a reliable and fail-safe work of wheels, an important quality characteristic of which is the hardness of the surface of the wheel rim. Today there are a lot of requirements to quality of wheels: ISO 6506-1, GOST 9012, GOST 10791, M-107 / M208, EN 13262.

Automated control system of railway wheels rim surface process skid was created to fulfill the railroad wheels quality requirements, and is based on EMKO hardness tester.

System features:

  • System provides an accurate all-axes positioning and the vertical axis positioning with binding to the outer surface of the rim wheel. Binding to the outer surface is made by using the high-precision absolute linear encoder that provides the required depth of the milling space for hardness measurement.
  • Information on the measured hardness is read from the measuring unit EMKO by means of the RS-232 interface and is shown on the operator panel.
  • Based on the data on the measurement of the hardness the system rejects the details, the hardness of which does not correspond to the requirements.
  • The record of amount of quality and defective items is kept automatically preserving the data in nonvolatile memory.
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