case study by sheetal wireless technologies pvt ltd … limited.pdf · stacker and reclaimer at acc...
TRANSCRIPT
CASE STUDY BY
SHEETAL WIRELESS TECHNOLOGIES PVT LTD
FOR
WIRELESS DATA COMMUNICATION BETWEEN
STACKER AND RECLAIMER AT ACC LIMITED
1
Success Case – Stacker and Reclaimer
Controlling & Monitoring Application
� Customer Information: ACC Limited Chandrapur, Maharashtra� Project handled by:
� FLSmidth Pvt Ltd. Chennai� Sheetal Wireless Technologies Pvt. Ltd. Pune� ABB Limited
� System Composition:
� Automation system consist of 3 nos. of Stackers and 3 nos. of Reclaimer moving on sixindependent rail tracks.
� Each Machine equipped with Siemens S7-300 (315-2DP) PLCs with Profibus Interface.� Each Machine equipped with Siemens S7-300 (315-2DP) PLCs with Profibus Interface.� Central Control Room equipped with ABB PLC AC800M with Profibus Interface.� MTL/Elpro, AUS Wireless Profibus Master & Slave Devices.
� Material Handled:
� Limestone, Coal and Additives.
� System Requirement:
� Remote monitoring and controlling of machines from CCR through wireless using Profibus asan interface.
� Physical signal interlock between machines (Discrete signal interlocks) and peer to peerProfibus communication, even in the absence of CCR.
� Transfer of PLC data (IO Signals and PLC information) using Profibus as a field-buscommunication.
2
Limestone Stacker-Reclaimer
M/C Control
CCR
Wireless Interlocking
Machine PLC
S7-300
Stacker
M/C PLC
S7-300
Reclaimer
Control Room ABB
PLC
3
Coal Stacker-Reclaimer
Wireless Interlocking
Profibus
Control Room PLC
Reclaimer
Stacker
Circular Stacker + ReclaimerProfibus interface
Profibus interface
4
Load Center
Additive Stacker-Reclaimer
Control
CCRWireless
InterlockingProfibus interface
Load Center
Machine PLC
Remote I/O
Stacker PLC
Machine PLC
Remote I/O
Reclaimer PLC
Control Room PLC
Profibus interface
Profibus interface
5
Site Photographs (Limestone Yard):
ReclaimerStacker
Rail Tracks
6
� Challenges:
� All the machines are inside the Shade and about 1Km from the control room.� All the Machines moving inside the shade.� Wireless communication system needs to work without Line Of Sight and also provide reliable
communication path from CCR to each of the machine while in motion.
� Solution:
� Wireless System with true Profibus interface supporting up-to 12Mbps over physicalinterface.
� Also with On-board discrete IO’s for Interlocking and exchanging Data in peer to peer modeof communication.Frequency band suitable for Non Line Of Sight operation, that is Licensed Band UHF (400-
About Overall System in Brief
� Frequency band suitable for Non Line Of Sight operation, that is Licensed Band UHF (400-500MHz)
� Achievements:
� True Profibus Interface allowing ABB PLC to work seamlessly up-to 12Mbps with localProfibus nodes.
� Successful installation of the Radio system and accessories for reliable RF Path.� Successful commissioning of the wireless system for exchange of Data between Siemens PLC
& ABB PLC using Profibus.� Successful transfer of IO information (about 32DI + 32DO + 16AI +16AO) comprising of
about 72 Bytes of data. Wireless system capable of transferring 200Bytes of Inputs + 200Bytesof Outputs.
� Successful exchange of data including physical IO signals between machines even in theabsence of CCR.
7
THANK YOU !!
8
CONTACT
Sheetal Wireless Technologies Pvt. Ltd.
Pune-411038, Maharashtra, INDIA
Ph. 91-20-25422941 / 25467179 / 64007732