AUTOMATED FISH TANK USING THE HUMAN- MACHINE INTERFACE (HMI)

Transcription

1 AUTOMATED FISH TANK USING THE HUMAN- MACHINE INTERFACE (HMI) Automated Fish Tank Author: Evelyn A. Chang and David Cheung Document Reference: COE 414 Requirements for Senior Project Proposal Date: January 12, 2004 PAGE 1 OF 26

2 TABLE OF CONTENTS TABLE OF CONTENTS... 2 ABSTRACT INTRODUCTION Project Initiation USER REQUIREMENT SPECIFICATION (URS) Introduction Performance Alarms FUNCTIONAL REQUIREMENT SPECIFICATION (FRS) Documenting Requirements System Overview / Description Process Overview Control System Programmable Controller and I/O Modules Production PC DESIGN SPECIFICATION Drawing Ladder Logic Program Wonderware Script Wonderware OIT Screen Shot PAGE 2 OF 26

3 4.5 Multimedia ActiveX Program WORK PLAN Methodologies Project Management BUDGET Feasibility Study QUALIFICATIONS BIBLIOGRAPHY ATTACHMENTS Attachment A Wonderware Specification Attachment B Equipment Specification Attachment C Loop Diagram Attachment D Configuration of Process Controls Attachment E PLC layout Attachment F Panel Layout Attachment G Input Wiring Diagram Attachment H Output Wiring Diagram Attachment I Network Wiring Diagram Attachment J Hydraulic Diagram Attachment K Ladder Logic Program Attachment L Preliminary Project Plan (GANTT Chart) PAGE 3 OF 26

4 PAGE 4 OF 26

5 ABSTRACT This project is intended to demonstrate that the automation and monitoring of a process can be applied to anything. Automation has been around for a long time in industry. It literally drives the manufacturing of a majority of products produced in our country. Our ideas are geared toward the consumer market to demonstrate that automation can also be applied in the home as well as industry. In our fast pace world, there is a need to monitor and control without actually being there. For example: a person may live in New Jersey but work in New York. That person may want to monitor and control his home from afar. The Internet and today s common network technology (i.e. Routers and PCs) have made this possible. This capability can give much flexibility to the consumer. In our case, our demonstration is used with a 12-gallon fish tank. A consumer may want to feed his/her fishes while he is on vacation. This project is designed to facilitate the monitoring and controlling of a 12-gallon fish tank from the Internet via Programmable Logic Controller (PLC) and the Human-Machine Interface (HMI) from a remote location. The project is comprised of various components that make up the automation process: HMI, PLC and I/O Modules, desktop Server (PC), remote desktop client, temperature transmitter, Resistance Temperature Detectors (RTD), Solenoid valves, level sensors, centrifugal pump, web cam, and other equipment. PAGE 5 OF 26

6 1 INTRODUCTION 1.1 Project Initiation The Wonderware InTouch application is a powerful graphical HMI for industrial automation, process control and supervisory monitoring. This software package was sponsored by the PF Laboratories, Inc. and the licensing support by the Q-Mation Co. The PLC controller transmits signal to the equipment to control equipment processes. From the equipment, a graphical and digital representation is displayed in the HMI. A PC and laptop would be utilized as workstations connecting to the PLC and Internet. A web cam is integrated to capture a live broadcast of the fish tank in live broadcast. The network traffic, equipment processing and equipment quality have been the rationale for time delays. The operator can visualize and control the process of the automated fish tank from any remote desktop that has the IP address. This document is being written retrospectively. The equipment has been purchased and the document is being written to adhere current requirements of the project. PAGE 6 OF 26

7 2 USER REQUIREMENT SPECIFICATION (URS) 2.1 Introduction This document is generated for the purpose of specifying the user requirement for controlling and monitoring the automated 12-gallon fish tank. 2.2 Performance NO. PERFORMANCE DESCRIPTION Remotely control and monitor automated process over the Internet View the process via web cam Turn on/off the light Drain the tank remotely Fill up the tank remotely Override logic to perform above maintenance Navigate between process and web cam windows Exit application View alarms from the web cam window. PAGE 7 OF 26

8 2.3 Alarms NO. PROCESS LEVEL_LOW LEVEL_HIGH SUPPLY_SV DRAIN_SV COMMENT Level Tank is full, supply and drain valve is closed X X X X Don't care Water is low, fill until 5 seconds past supply valve closure Tank is empty, supply valve is on and drain valve is closed Drain X X 0 1 Manually drain tank Feed X X X X Feeder is turned on every 6 hours Light X X X X Manually turn on light Legend: 0 Off 1 On X Don t care PAGE 8 OF 26

9 3 FUNCTIONAL REQUIREMENT SPECIFICATION (FRS) 3.1 Documenting Requirements This Specification section of this document applies to the automated 12-gallon fish tank. The specification document lists the functionality of the automated fish tank system and details the major hardware, software, and process equipment components. 3.2 System Overview / Description Automated Fish Tank The automated fish tank system is designed for users needs to monitor and control their fish tank via Internet. It is composed of several major components that include the fish tank, a pump unit, float switches, relay contactor, a temperature transmitter, a duplex element RTD, solenoid valves, light, and PLC system. The pumping system draws water into the system. The float switches are designed for measuring water levels. One switch is wired for high water level and the other switch is design for low water level. This equipment is a Polysulfone float that is used for shallow tanks or restricted spaces. This small size, engineered plastics offer high reliability; compact size and low cost in NPT, straight and metric threads is used in measuring the water tank level. The normally open relay contactors are utilized specifically for the control of lights and the pump. The relays have the ability to switch higher current loads than the PLC output card. PAGE 9 OF 26

10 The temperature transmitter is used to gather temperature variables and displays the current value to the interface. This device receives analog signals and transmits the temperature result in electrical signal, milliamps, to the PLC through hard-wired relays. This equipment is two-wire, microprocessor-based, PC programmable, head or rail mount temperature transmitter that accepts platinum and nickel RTD, ohms, millivolts, and thermocouple inputs. The duplex element RTD has two measuring elements within a single sheath and is designed to measure temperature in a variety of process applications. The duplex element RTD is specifically designed for use in two different process temperature ranges and it provides accurate and repeatable temperature measurement through a broad range of 328 deg to 1112 deg F (-200 deg to 600 deg C). The duplex RTD is used to produce a linearized (4 to 20) ma dc output current signal, which is directly proportional to the temperature of the RTD temperature-sensing element. The solenoid valves are used to control the flow of the water either from going to the tank or leaving the tank. Other equipment that is used to operate the system is the operator interface and the PLC controllers. The operator interface panel contains a mouse and keyboard that allows the operator to control the operation of the process. The PLC control panel houses the Allen Bradley PLC and other electric/pneumatic equipment that is used to control the process. The process begins when a recipe is entered at the operator interface terminal (OIT). The pre-programmed recipe is selected and put into active registers in the PLC. The entire processor and all its components are controlled by the PLC. The operator communicates via the OIT. PAGE 10 OF 26

11 3.3 Process Overview The automated fish tank is used in the following two capacities: Function: Filling Process The filling process allows the system to open the supply solenoid and turn the pump on. The status of the pump, water level, and the supply valve indicator is shown in the navigation screen Function: Draining Process The draining process allows the system to open the drain solenoid valve. The status of the water level and the drain valve indicator is shown in the navigation screen. 3.4 Control System The Control System processes information about an operation and sends signals to the equipment to operate according to the desired. The Control System includes the Operator Interface Terminal (OIT), the Allen-Bradley Programmable Logic Controller (PLC), and field control devices. The PLC 500 system is a reliable stand-alone control device that offers flexibility in system configurations. This communication device is for remotely controlling electrical devices over standard electrical wiring. The fixed controller provides the power supply, inputs and outputs, and processor in one unit. It also offers a 2-slot expansion chassis for increased flexibility. The OIT workstation is a computer operating on a Microsoft Windows XP Professional with a Pentium processor that is running a version of graphical In-Touch operator interface software by Wonderware. The station is used for process overview, maintenance, alarming, and control. PAGE 11 OF 26

12 The Main PLC Panel continuously monitors process conditions via analog and digital inputs from field instrumentation and performs adjustments to the process via interlock logic, PID control, and alarm checking. 3.5 Programmable Controller and I/O Modules An Allen-Bradley programmable controller performs the process control and automation functions. The logic is performed in a SLC 5/05 processor. This is a single slot device, which can perform an advanced set of logical and mathematical functions. The processor is installed in a 4-slot rack along with power supply and necessary input and output modules. The high performance processor provides standard Ethernet communications. It also provides network for program upload/download, on-line editing, and peer-to-peer messaging I/O Modules Refer to Attachment A Wonderware Specification and Attachment B Equipment Specification for detail list of the I/O modules PAGE 12 OF 26

13 3.6 Production PC This project is composed of extreme software programming and hardware installation. Among the requirements of this project were listed, as follows: Software The software packages to be installed shall be: NO. SOFTWARE / VERSION Microsoft Windows Server Wonderware InTouch 7.1 / Wonderware OPC Link Wonderware I/O Server RS Logix 500 MINIMUM HARDWARE AND SOFTWARE REQUIREMENTS Minimum CPU Speed 400 MHz Pentium II Suggested CPU Speed 1.2 GHz Pentium III or greater Minimum RAM 256 MB, plus 5 bytes RAM per 5K tags Suggested RAM 512 MB Disk Space 5 GB Free Hard Disk space OPERATING SYSTEM Microsoft Windows XP with SP1 PAGE 13 OF 26

14 3.6.2 Hardware The hardware components shall be: The server is used for storage device of all the software applications needed to implement the project. This is also used to interface with the PLC to display the process variables, such as the temperature, light indicator, etc. MICROSOFT WINDOWS SERVER 2003 SYSTEM REQUIREMENTS Minimum CPU Speed Recommended CPU Speed Minimum RAM Recommended Minimum RAM Maximum RAM Disk Space for Setup 133 MHz 550 MHz 128 MB 256 MB 4 GB 1.5 GB * Important: The 64-bit versions of Windows Server 2003, is only compatible with 64-bit Intel Itanium-based systems. They cannot be successfully installed on 32-bit systems. PAGE 14 OF 26

15 4 DESIGN SPECIFICATION 4.1 Drawing NO. DRAWING DRESCRIPTION Loop Diagram Configuration of Process Controls PLC Layout Panel Layout Input Wiring Diagram Output Wiring Diagram Network Wiring Diagram Hydraulic Diagram 4.2 Ladder Logic Program Refer to Attachment K Ladder Logic Program for detail of the logic of the program. PAGE 15 OF 26

16 4.3 Wonderware Script / Tag Name PAGE 16 OF 26

17 4.4 Wonderware OIT Screen Shot Operator Interface PAGE 17 OF 26

18 DATE: 11-MAR-03 COMPUTER ENGINEERING PROJECT PROPOSAL Subject: AUTOMATED FISH TANK Process Monitoring Interface PAGE 18 OF 26

19 DATE: 11-MAR-03 COMPUTER ENGINEERING PROJECT PROPOSAL Subject: AUTOMATED FISH TANK Web cam Interface PAGE 19 OF 26

20 DATE: 11-MAR-03 COMPUTER ENGINEERING PROJECT PROPOSAL Subject: AUTOMATED FISH TANK 4.5 Windows Media Encoder The Microsoft Widows Media Encoder SDK is utilized to develop a button. The button displays live images through a web cam. The WindowMaker supports ActiveX controls which, in their simplest form, are mini-applications that talk to or run the design interface. The WindowMaker supports all ActiveX controls that are included in Wonderware FactorySuite components that were utilized in this project. PAGE 20 OF 26

21 DATE: 11-MAR-03 COMPUTER ENGINEERING PROJECT PROPOSAL Subject: AUTOMATED FISH TANK 5 WORK PLAN 5.1 Methodologies PAGE 21 OF 26

22 DATE: 11-MAR-03 COMPUTER ENGINEERING PROJECT PROPOSAL Subject: AUTOMATED FISH TANK 5.2 Project Management Project Team and Responsibilities MEMBER NAME ROLE RESPONSIBILITIES David Cheung Project Manager Problem Statement Networking Programming the PLC (Ladder Logic) Hardware and Software configuration Web Cam Installation and Configuration Evelyn Chang Assistant Project Manager Designing the Front End Interface Designing Web Server for the HMI Requirement Specifications Feasibility Studies Resource Management Assisting in programming the PLC (Ladder Logic) Resource Management Preliminary Project Plan (GANTT Chart) the schedules. Refer to Attachment L Preliminary Project Plan (GANTT Chart) for details of PAGE 22 OF 26

23 DATE: 11-MAR-03 COMPUTER ENGINEERING PROJECT PROPOSAL Subject: AUTOMATED FISH TANK 6 BUDGET 6.1 Feasibility Study Economic Feasibility (As of April 21, 2003) ONE-TIME COST WORKSHEET AUTOMATED FISH TANK A. New Software (Wonderware FactorySuite 2000) $ 0 B. New Allen Bradley Processor (Part No. SLC 5/05) $ C. New Allen Bradley I/O Module (Part No OA12) $ D. Server (Microsoft Windows XP Professional) $ E. Pump $80 F. Tube $ 20 G. Sanitary Fittings $ 25 H. Switch $ I. Miscellaneous $ TOTAL One-Time Costs $ PAGE 23 OF 26

24 DATE: 11-MAR-03 COMPUTER ENGINEERING PROJECT PROPOSAL Subject: AUTOMATED FISH TANK 7 QUALIFICATIONS Our Remote Fish Tank idea was based on our previous internship with PF Laboratories, Inc. Our former supervisor is, to this day, continuously supporting our pursuit of automated manufacturing processes. He has taught us many concepts of automation and industrial processes in most manufacturing facilities. Thus, has motivated us to pursue a project in this area of engineering. David Cheung ( is the Project Manager in the aspect of Networking. He has knowledge in the field of IT networking and programming as well as Hardware & Software Configurations from previous internship. David has built 3 personal servers and over 15 personal computers. During his internship experience, he had validated servers in compliant with the stringent rules and regulations of the FDA, cloned and reconfigured over hundreds of PCs, and troubleshoot networking problems. His intellect and knowledge about computers is an asset to our project. In addition, his experience in the Military as a Direct Supervisor, he can supervise the team with no hassle. Evelyn A. Chang ( is the Project Manager in the aspect of Graphical Design Interface (GUI) and Project Management. During Evelyn s educational experience, she had learned and understood the concepts of designing the industrial processes via HMI software and writing protocols for validation purposes. She has also the limited knowledge of designing and creating a Human Machine Interface utilizing Wonderware Factory Suite 2000 (Intouch 7.1/7.11). The Intouch 7.1/7.11 maker will help her in designing the interface. Both, Evelyn and David, will team up in a project called Automated Fish Tank using Human- Machine Interface. PAGE 24 OF 26

25 DATE: 11-MAR-03 COMPUTER ENGINEERING PROJECT PROPOSAL Subject: AUTOMATED FISH TANK 8 BIBLIOGRAPHY Chang, Evelyn A, et al, eds. Human Machine Interface. New Jersey Institute of Technology: Project Proposal. < InTouch 8.0 Data Sheet. Wonderware Corporation. Invensys System, Inc. Rev. 1/03. Mar. 03, < Wonderware FactorySuite InTouch 7.1/7.11 User Guide, Rev. C, July Wonderware FactorySuite InTouch 7.1/7.11 Reference Guide, Rev. C, July Wonderware FactorySuite IndustrialSQL Server Administration Guide, Rev. A, 15 May Wonderware FactorySuite IndustrialSQL Server Database Reference, Rev. A, 15 May Wonderware MaintenanceSuite Introduction, PN , March Allen Bradley Literatures PAGE 25 OF 26

26 DATE: 11-MAR-03 COMPUTER ENGINEERING PROJECT PROPOSAL Subject: AUTOMATED FISH TANK 9 ATTACHMENTS 9.1 Attachment A Wonderware Specification 9.2 Attachment B Equipment Specification 9.3 Attachment C Loop Diagram 9.4 Attachment D Configuration of Process Controls 9.5 Attachment E PLC layout 9.6 Attachment F Panel Layout 9.7 Attachment G Input Wiring Diagram 9.8 Attachment H Output Wiring Diagram 9.9 Attachment I Network Wiring Diagram 9.10 Attachment J Hydraulic Diagram 9.11 Attachment K Ladder Logic Program 9.12 Attachment L Preliminary Project Plan (GANTT Chart) PAGE 26 OF 26