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Printing Machine Computer Based Control System

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Printing Machine Computer Based Control System Printing Machine Computer Based Control System Sayed Haroon Shadad A thesis submitted to University of Khartoum, the Faculty of Engineering, Department of Electrical and Electronic Engineering, in complete fulfillment of the requirements for the degree of Masters of Science In Electrical & Electronic Engineering Supervisor: Dr. Sami Mohamed Sharif 2004 Keywords: printing, machine, computer based, control ﺑﺴﻢ اﷲ اﻟﺮﺣﻤﻦ اﻟﺮﺣﻴﻢ (وءاﺗﺎآﻢ ﻡﻦ آﻞ ﻡﺎ ﺱﺄﻟﺘﻤﻮﻩ وإن ﺗﻌﺪوا ﻧﻌﻤﺖ اﷲ ﻻ ﺗﺤﺼﻮهﺎ إن اﻹﻧﺴﺎن ﻟﻈﻠﻮم آﻔﺎر) اﻵیﺔ (٣٤) ﻡﻦ ﺱﻮرة إﺑﺮاهﻴﻢ i Dedication To my daughters and sons: “A little knowledge is a dangerous thing---incomplete knowledge about a subject is sometimes worse than no knowledge at all” ii AKNOWLEDEMENT First, I would like to express my thanks to Allah for his great help in the completion of this thesis. I would like to express my sincere thanks to my supervisor, Dr Sami Mohamed Sharif for his fruitful efforts, guidance and interest. My thanks to Dr. Ezeldeen Kamil Amin, for his advice and encouragement. I would like to express my deep thanks to all the staff in my company; Sudan Currency printing Press (SCPP) represented by the General Manager Dr. Hassan Omer A/Rahman for his great assistance and encouragement and for taking the burden of the costs of the project. My, deep thanks to the following colleagues for their kind support in the gloomy days: ¾ Mustafa Arena Computer Engineer. ¾ Al Doma Al Bager Electrical Technician. ¾ Tag Al Sir Mohammed Electrical Technician. iii اﻟﺨﻼﺻﺔ ﺗﻤﺘﻠﻚ ﺷﺮآﺔ ﻡﻄﺎﺑﻊ اﻟﺴﻮدان ﻟﻠﻌﻤﻠﺔ اﻟﻮرﻗﻴﺔ ﻋﺪد ﻡﻦ ﻡﺎآﻴﻨﺎت اﻟﻄﺒﺎﻋﺔ و هﻨﺎك ﺱﺘﺔ ﻡﻦ هﺬﻩ اﻟﻤﺎآﻴﻨﺎت ﺗﻌﺘﺒﺮ ﻗﺪیﻤﺔ ﻧﺴﺒﻴﺎ. و رﻏﻢ اﻷداء اﻟﺠﻴﺪ ﻟﻬﺬﻩ اﻟﻤﺎآﻴﻨﺎت ﻡﻦ اﻟﻨﺎﺣﻴﺔ اﻟﻤﻴﻜﺎﻧﻴﻜﻴﺔ, إﻻ أﻧﻬﺎ ﺗﻌﺎﻧﻰ ﻡﻦ ﻡﺸﺎآﻞ آﻬﺮﺑﺎﺋﻴﺔ ﻡﺘﻜﺮرة؛ ﻷن ﻧﻈﺎم اﻟﺘﺤﻜﻢ ﻓﻲ هﺬﻩ اﻟﻤﺎآﻴﻨﺎت ﺗﻘﻠﻴﺪي و ﻗﺪیﻢ و یﻌﺘﻤﺪ ﻋﻠﻰ ﻋﻤﻞ اﻟﻤﺒﺪﻻت وأیﻀﺎ هﻨﺎك ﺹﻌﻮﺑﺔ ﻓﻰ اﻟﺤﺼﻮل ﻋﻠﻰ ﻗﻄﻊ ﻏﻴﺎر ﻟﻬﺬا اﻟﻨﻈﺎم؛ ﻷن ﻡﻌﻈﻢ اﻟﻘﻄﻊ اﻟﻜﻬﺮﺑﺎﺋﻴﺔ ﻓﻰ ﻧﻈﺎم اﻟﺘﺤﻜﻢ اﻟﻤﺬآﻮر إﻡﺎ ﺗﻮﻗﻒ اﻧﺘﺎﺝﻬﺎ أ و ﺗﻢ ﺗﺤﺪ یﺜﻬﺎ, واﻷﺧﻴﺮة هﻨﺎك ﺹﻌﻮﺑﺎت ﻓﻨﻴﺔ ﻓﻲ ﺗﺮآﻴﺒﻬﺎ ﻋﻮﺽﺎ ﻋﻦ اﻟﺘﺎﻟﻔﺔ. و ﻧﺘﻴﺠﺔ ﻟﻜﺜﺮة اﻟﻤﺸﺎآﻞ اﻟﻜﻬﺮﺑﺎﺋﻴﺔ ﺗﺪﻧﺖ إﻧﺘﺎﺝﻴﺔ هﺬﻩ اﻟﻤﺎآﻴﻨﺎت؛ ﻟﺬا ﺗﻢ إﺧﺘﻴﺎر واﺣﺪة ﻡﻦ هﺬﻩ اﻟﻤﺎآﻴﻨﺎت ﻟﺘﺤﺪیﺚ ﻧﻈﺎم ﺗﺤﻜﻤﻬﺎ. ﺗﻢ إﺧﺘﻴﺎر ﻧﻈﺎم اﻟﺘﺤﻜﻢ اﻟﻤﺒﻴﺖ ﻟﻴﺤﻞ ﻡﻜﺎن ﺗﺤﻜﻢ اﻟﻤﺒﺪﻻت، وهﺬا اﻟﻨﻈﺎم أﺹﺒﺢ واﺱﻊ اﻻﻧﺘﺸﺎر و ﺑﺪأ یﺤﻞ ﻡﻜﺎن ﻧﻈﺎم اﻟﺤﺎآﻤﺔ اﻟﻤﻨﻄﻘﻴﺔ اﻟﻤﺒﺮﻡﺠﺔ اﻟﺬاﺋﻌﺔ اﻟﺼﻴﺖ. وﻟﺘﺼﻤﻴﻢ هﺬا اﻟﻤﺸﺮوع ﺗﻢ ﺗﺤﺪیﺪ ﻡﺪاﺧﻞ و ﻡﺨﺎرج ﻡﺎآﻴﻨﺔ اﻟﻄﺒﺎﻋﺔ اﻟﻤﻌﻨﻴﺔ و آﺬﻟﻚ ﺗﻢ ﺣﺴﺎب ﻗﻴﻢ اﻟﻔﻮﻟﺖ و اﻟﺘﻴﺎر ﻟﺪواﺋﺮ اﻟﻤﺪاﺧﻞ و اﻟﻤﺨﺎرج , وﺗﻢ ﺷﺮح ﺗﺴﻠﺴﻞ ﻋﻤﻞ اﻟﻤﺎآﻴﻨﺔ ﻓﻰ ﻡﺨﻄﻂ ﺱﺮیﺎن, آﺬﻟﻚ ﺗﻢ ﺣﺴﺎب ﺱﺮﻋﺔ اﻟﻤﻌﺎﻟﺠﺔ اﻟﺪﻧﻴﺎ ﻟﻸﻡﺮ و ذﻟﻚ ﻟﺘﺤﺪیﺪ اﻟﺴﺮﻋﺔ اﻟﻤﻄﻠﻮﺑﺔ ﻟﻠﻤﻌﺎﻟﺞ اﻟﺪﻗﻴﻖ. اﻟﻤﻌﻠﻮﻡﺎت اﻟﻤﺬآﻮرة أﻋﻼﻩ ﺗﻢ اﻻﺱﺘﻔﺎدة ﻡﻨﻬﺎ ﻻﺧﺘﻴﺎر ﻧﻮع اﻟﻨﻈﺎم اﻟﻤﺒﻴﺖ ووﻗﻊ ﻟﻼﺧﺘﻴﺎر ﻋﻠﻰ ﺝﻬﺎز اﻟﺤﺎﺱﻮب اﻟﺸﺨﺼﻰ یﺤﻤﻞ اﺱﻢ أوروﺑﺎ اﻟﻘﻴﺎﺱﻰ و ﺗﻢ ﺗﺼﻨﻴﻌﻪ ﺑﻮاﺱﻄﺔ ﺷﺮآﺔ ﺁرآﻮم ﺑﺎﻟﻤﻤﻠﻜﺔ اﻟﻤﺘﺤﺪة. آﺬﻟﻚ ﺗﻢ ﺷﺮاء ﺑﻘﻴﺔ اﻟﻤﻮاد اﻟﺘﻰ یﺤﺘﺎﺝﻬﺎ ﺗﺼﻨﻴﻊ ﻟﻮﺣﺔ اﻟﺘﺤﻜﻢ؛ ﻡﺜﻞ اﻟﻘﻮاﻃﻊ اﻟﻜﻬﺮﺑﺎﺋﻴﺔ, أﺝﻬﺰة اﻟﺘﻼﻡﺲ و أﺝﻬﺰة اﻟﺤﻤﺎیﺔ ﻡﻦ زیﺎدة اﻟﺤﻤﻞ و ﻡﺤﺮك یﻌﻤﻞ ﺑﺎﻟﺘﻴﺎر اﻟﻤﺴﺘﻤﺮ و ﻡﻌﻪ اﻟﻤﻐﻴﺮ اﻟﻜﻬﺮﺑﺎﺋﻰ...اﻟﺦ. ﺹﻨﻌﺖ اﻟﻠﻮﺣﺔ و ﻡﻦ ﺙﻢ ﺗﻤﺖ آﺘﺎﺑﺔ اﻟﺒﺮﻧﺎﻡﺞ اﻟﺨﺎص ﺑﺎﻟﻤﺎآﻴﻨﺔ ﺑﺎﻻﻋﺘﻤﺎد ﻋﻠﻰ ﻟﻐﺔ ﻡﻴﻜﺮوﺱﻔﺖ اﻟﻤﺮﺋﻴﺔ اﻟﻤﺒﻴﺘﺔ-3.0, ﺗﻢ ﺗﺤﻤﻴﻠﻬﺎ ﻓﻰ ﺝﻬﺎز ﺣﺎﺱﻮب ﺷﺨﺼﻰ ﺑﻪ ﻧﻈﺎم اﻟﺘﺸﻐﻴﻞ ویﻨﺪووز ٢٠٠٠, ﺑﻌﺪ ذﻟﻚ ﺗﻢ ارﺱﺎل اﻟﺒﺮﻧﺎﻡﺞ ﻟﺠﻬﺎز اﻟﻨﻈﺎم اﻟﻤﺒﻴﺖ اﻟﺬى ﺑﻪ ﻧﻈﺎم وﻧﺪووز ﺱﻰ. اى 3.0 , وﻡﻦ ﺙﻢ ﺗﻤﺖ ﻋﻤﻠﻴﺔ اﻟﻤﺤﺎآﺎة و إزاﻟﺔ اﻷﺧﻄﺎء ﻡﻦ اﻟﺒﺮﻧﺎﻡﺞ و ﺗﺸﻐﻴﻞ اﻟﻤﺎآﻴﻨﺔ. اﻟﻤﺤﺼﻠﺔ اﻟﻨﻬﺎﺋﻴﺔ أن ﻋﻤﻠﺖ اﻟﻤﺎآﻴﻨﺔ ﺑﺼﻮرة ﻡﺮﺽﻴﺔ و آﺬﻟﻚ ﺗﻢ ﺗﺰویﺪ اﻟﻨﻈﺎم اﻟﻤﺒﻴﺖ ﺑﺨﺎﺹﻴﺔ ﺗﺸﺨﻴﺺ اﻷﻋﻄﺎل. وﺑﻤﺎ أﻧﻰ ﻗﻤﺖ ﺑﻬﺬ اﻟﻌﻤﻞ ﺑﻨﻔﺴﻰ دون أن أآﻠﻒ ﺝﻬﺔ أﺧﺮى, ﻓﻠﻘﺪ ﺗﻢ ﺗﻮﻓﻴﺮ ﻡﺎﺋﺔ أﻟﻒ یﻮرو. iv ABSTRACT Sudan Currency Printing Press (SCPP) has six old printing machines; but they are mechanically functioning well. The machines encounter many electrical problems, because of their old relay based control system, besides its disadvantages, there is a lack of spare parts for the control cabinets; their electrical components are no longer produced or have been superseded by newer designs. Therefore, these machines are constantly stopping due to electrical faults, which render low production. The computer based control system was selected to replace the relay based control system. For the design of this system, the number and type of inputs and outputs has been found, voltage and current required to supply the control circuits of those I/Os have been decided, and the sequence of operation of the machine has been explained in a flow chart. In addition, the minimum processing speed needed for the instruction has been calculated. The above information was used as a guide for selecting the type of the embedded based control system. Standard Europe Personal Computer, made by Arcom Company, was selected as a new control system for the machine and purchased. Other material like circuit breakers, contactors, overloads, DC motor with it is converter…etc. has been purchased, then the control cabinet was built, after that the software development was made by using Microsoft Embedded Visual C++ 3.0 running on Windows 2000 desktop workstation, then transferred to the embedded computer which has windows CE 3.0 operating system. At last debugging, simulation and commissioning of the project have been done. As a result, the machine runs smoothly for production without any problem deserve mentioning, and a powerful diagnostic feature for faultfinding was added. Spare parts for this system are available. Instead of giving this project to a company to do it, I did it by my self; accordingly, there is a saving of One Hundred Thousand EURO. v Tables of Contents Quran .....................................................................................................................................................................i Dedication ...........................................................................................................................................................ii Acknowledgement.............................................................................................................................................iii Abstract (Arabic).............................................................................................................................................. .iv Abstract (English).............................................................................................................................................. v Table of Contents............................................................................................................................................. vi List of Figures.................................................................................................................................................... ix List of Tables.......................................................................................................................................................x 1. Introduction................................................................................................................................................... 1 2. Chapter Two................................................................................................................................................... 4 2.1 What Is the Numbering Machine ..................................................................................................... 4 2.2 The Feeding Unit ................................................................................................................................. 5 2.2.1 Operation of the Feeder........................................................................................................... 6 2.2.2 Non-Stop Operation................................................................................................................. 7 2.3 Registration Unit .................................................................................................................................. 7 2.4 The Printing Unit................................................................................................................................. 8 2.4.1 The Cylinder System ................................................................................................................. 8 2.4.2 The Inking Unit.......................................................................................................................... 9 2.5 Delivery Unit................................................................................................................................ 10 3. Chapter Three............................................................................................................................................. 12 3.1 What are The PIDS and The PLCS ............................................................................................... 12 3.2 The Proportional, Integral and Derivative Controllers............................................................... 12 3.2.1 Feedback System...................................................................................................................... 12 3.2.2 On-Off Control ....................................................................................................................... 14 3.2.3 Proportional Mode .................................................................................................................. 14 3.2.3.1 Offset ........................................................................................................................... 14 3.2.3.2 Applications ................................................................................................................ 15 3.2.4 Integral Mode ........................................................................................................................... 18 3.2.5 Proportional Plus Integral Controller .................................................................................
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