Claims:CLAIMS

1. A system for real time remote diagnostics & control of PLC & HMI for moving machines, the system comprising: the project site seamlessly connected and the monitoring centre platform, construction site, including equipment connected in sequence, the input and output signal acquisition, PLC controller, network interface and within local Wi-Fi Zone, wherein the HMI includes a set of functional modules stored within a human-machine interface for generating configurable views to be displayed on a display, for interpreting inputs received via an input device, for processing parameter signals received from remote devices and for generating output signals for reporting to or controlling remote equipments (SCR), the set of functional modules adapted for uploading to a configuration station, and a set of screen instructions for generating the configurable views and calling upon the functional modules based upon inputs received via the input device; and wherein the network interface is configured to receive the parameter values and send the output signals in an industrial data exchange protocol.

2. A system as claimed in claim 1, wherein: the functional modules stored within the human-machine interface are adapted for generating configurable views to be displayed on a display, for interpreting inputs received via an input device, for processing parameter signals received from remote devices and for generating output signals for reporting to or controlling remote devices, the set of functional modules adapted for uploading to a configuration station;
a set of screen instructions for generating the configurable views and calling upon the functional modules based upon inputs received via the input device; and
a network interface configured to receive the parameter values and send the output signals in an industrial data exchange protocol.

3. A system as claimed in claim 1, wherein the HMI in Panel view system is configured to identify the moving SCRs and is accessed from CCR wirelessly for monitoring & control of SCR machines.

4.A system as claimed in claim 1, wherein the PLC & Panel View system are accessed from anywhere within the Wi-Fi zone in real time.

5. A system as claimed in claim 1, wherein the real-time data is accessed to judge site equipment operation status online.

Dated: this 08th day of March, 2016.

(N. K. Gupta) Patent Agent, Of NICHE,
For SAIL.

To,
The Controller of Patents, The Patent Office, Kolkata.
, Description:SYSTEM FOR REALTIME REMOTE DIAGNOSTICS & CONTROL OF PLC & HMI FOR MOVING MACHINES.

FIELD OF THE INVENTION:

The present invention relates to real time Remote Diagnostics & Control of PLC & HMI for moving Machines. More particularly, the present invention relates to system for remote diagnosis and control for stacker cum re-claimers, loaders, conveyors etc.

BACKGROUND OF THE INVENTION:

There are 4 Stacker cum Re-claimers (SCR) having capacity 900TPH in RMHP, DSP. These SCRs are used for stacking as well as reclaiming. Two SCRs are used for Iron ore & two for fluxes.

Wireless system based Automation scheme has been developed for all 4 SCR machines. Communication between SCR & Operator Cabin has been established through redundant single communication cable eliminating all multi-core control cables. PLC compatible Intelligent Operator Desks with Panel View facility act as soft operator input as well as on-line operator feedback system for instantaneous corrective action resulting in SCR electrical downtime arising due to huge cable fault. PLC data can be accessed from CCR, 2.5 KM away from moving SCRs. PLC program can be uploaded / downloaded from remote CCR wirelessly. Any change in control philosophy can be easily achieved through soft logic in place of earlier complex hard wired relay based control circuits which was difficult to modify, maintain. The online diagnostics available makes it easier for troubleshoot.

HMI in Panel view system developed in the moving SCRs & can be accessed from CCR wirelessly for monitoring & control of SCR machines. PLC & Panel View system can also be accessed from anywhere within the Wi-Fi zone for on-line remote diagnostics, monitoring & control of SCR machines.

With the new system frequent downtime of SCR machine can be minimized significantly resulting in increase in machine availability & reduction of demurrage. It

helps in taking immediate corrective action in case of any electrical breakdowns. A new additional HMI facility has also been developed in CCR & is interfaced with existing dispatchers. Status of the SCR machines is also available in the whole RMHP area.

LIMITATION OF THE EXISTING METHODS

In the existing system, communication between Operator Cabin to PLC Control Room is made through hard wired control cables. These control cables are prone to frequent damages, which result delay in stacking & reclaiming operation. Earlier annunciation system was also not working properly. Also there was no communication facility available between SCRs and Central Control Room (CCR) & various RMHP Dispatchers. Earlier annunciation facility was not working properly resulting in pinpointing the trouble area.

• Breakage of signal cables between Operator Cabin & PLC Room of the SCRs results in stoppage of the machine hence delay in stacking & reclaiming
• Multi-core control cables give frequent maintenance problems

• Any breakdown in SCR m/c affects stacking, reclaiming, tippling & blend mix production affecting hot metal production & high demurrage
• Poor annunciation system in Operator Cabin of the SCR machine

• Absence of online diagnostics leads to delays in corrective action

• No centralised HMI system for SCR machines

• Absence of any feedback system in CCR (Central Control Room) & lack of coordination between SCR & CCR

SUMMARY OF INVENTION

Therefore such as herein described there is provided a system for realtime remote diagnostics & control of PLC & HMI for moving machines, the system comprising: the project site seamlessly connected and the monitoring center platform, construction site, including equipment connected in sequence, the input and output signal acquisition, PLC controller, network interface and 3G Wireless Router wherein the HMI includes a set of functional modules stored within a human- machine interface for generating configurable views to be displayed on a display,

for interpreting inputs received via an input device, for processing parameter signals received from remote devices and for generating output signals for reporting to or controlling remote equipments (SCR), the set of functional modules adapted for uploading to a configuration station, and a set of screen instructions for generating the configurable views and calling upon the functional modules based upon inputs received via the input device; and wherein the network interface is configured to receive the parameter values and send the output signals in an industrial data exchange protocol.

Further herein disclosed is a system wherein the functional modules stored within the human-machine interface are adapted for generating configurable views to be displayed on a display, for interpreting inputs received via an input device, for processing parameter signals received from remote devices and for generating output signals for reporting to or controlling remote devices, the set of functional modules adapted for uploading to a configuration station; a set of screen instructions for generating the configurable views and calling upon the functional modules based upon inputs received via the input device; and a network interface configured to receive the parameter values and send the output signals in an industrial data exchange protocol.

OBJECTS OF THE INVENTION

A basic object of the present invention is to provide a modified system having control desk with remote I/O & Panel View inside the control desk.

Another object of the present invention is to provide an improved system that render provision of testing the Control Desk electrical wirings, interlocks and plant logics well before actual installation and hence significantly reducing final installation as well as commissioning time.

Yet another object of the present invention is to provide direct connectivity with moving PLC of SCR machine avoiding huge requirement of multi-core control cables.

These and other advantages of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

Fig. 1 shows “Soft Intelligent Control Desk” & Panel view system inside Operator Cabin for various operations of moving SCR in accordance with the present invention;

Fig. 2 illustrates Remote I/O system inside Operator Control Desk;

Fig. 3 shows a Control Desk mounted Panel View for SCR operations through soft input & on-line Operator feedback system;

Fig. 4 illustrates the HMI screen snap shot of Panel View for various operations of moving SCR in accordance with the present invention;

Fig. 5 illustrates accessing SCR PLCs & HMIs by Plant Electrical, developed in

Panel Views inside Operator Cabins.

DETAILED DESCRIPTION

The Result of automation is visible in various areas of industry as well as in routine life. Automation makes the process control more efficient, increases productivity of work, manufacturing quality, decreases manufacturing costs. Automation is still in development so that it could succeed in filling all requirements of today’s technical advance. For this reason the implementation of automation systems, their handling and expanding in coal handling industries is required. The System includes the field automation of production plant and the Centralized monitoring control center. The field automated production center uses the TCP-IP (Ethernet) protocol to build a network, connect every controller to Profibus than by convertor connect to the control network. Feedback value of belt weighed feed rate & totalize of Re-claimer continuously monitor. Control center SCADA & PLC control the system. Multi workstation systemize by running the monitor software WINCC7.3 to connect via Ethernet module (Scalalance) of PLC system, Real time data control and management of the entire system can be differed as per requirement of user. Re -

claimer related events, alarm etc. logged in to SCADA. Data also continuously archive by server for long history.

Material handling system have large network. Which have various equipment’s for stacking the material such as coal, ore etc in yard & reclaiming the material from yard. This all equipment like Grab sip unloaders, Stacker cum re-claimers, Receiving conveyors , Dispatch conveyors, sprigling system etc. have own control logic HMI & PLC. For centralize control of this large material handling system equipment’s require SCADA system & PLC which is continuously control & manage real time data continuously. Principle of the SCADA & PLC base automatic blending system is that the belt weigher of Reclaimer give present flow rate & totalizer real- time online data and according to constraints condition and set point objectives, to build a reasonable logical flow chart and dynamic optimum ratio, use closed-loop control for Reclaimer slew & long traveling speed control techniques. By this one can archive quality of blended materials near to requirement, so the material blending is more stable, reliable and accurate. The automated control system is more automatic, reducing the involvement of staff, to improve loading speed and reliability, to maximize the use of the Reclaimer equipment, full use of existing resources and cost savings.

BASIC COMPONENTS OF THE PRESENT INVENTION:

• Wireless system based automation scheme has been developed in Stacker cum Reclaimer zone of RMHP area of DSP. Four Wireless systems have been installed & commissioned for centralized monitoring & control for all the four SCR machines from Central Control Room (CCR).
• Network based Wireless system is developed with unlimited I/O capabilities for remote access to HMI & PLCs installed in moving machines enabling uploading / downloading PLC software program from a remote location.
• Remote & wireless access of HMI system developed in Panel View in moving machines within dedicated Wi-Fi Zone.

• PLC compatible Panel View systems have been commissioned for soft Operator Input (SCR operation) as well On-line Operator feedback system for instantaneous corrective action resulting in SCR electrical downtime arising due to huge cable fault.
• PLC data can be accessed from CCR, 1.5 KM away from moving SCRs. PLC program can be uploaded / downloaded from remote CCR wirelessly.
• HMI in Panel view system developed in the moving SCRs & can be accessed from CCR wirelessly.
• PLC & Panel View system can also be accessed from anywhere within the

Wi-Fi zone for on-line remote diagnostics.

• Remotely & wirelessly Software modification of application program is possible. Provision for wirelessly remote Man-less operation of the moving machine provided.

The Remote Diagnosis and control system herein described includes, 3G wireless router using high-performance processor and perfect of software and hardware watchdog mechanism, built-in 10 / 100MbpS Ethernet interfaces, having a 2. 5G /
3G networking function, support GPRS / EDGE / WCDMA, CDMA lx / EVDO, TD- SCDMA standard (different networks, different models), may the access all over the world most of the mobile operator network; having VPN function, support IPkc VPN, facilitates one to monitor center direct access remote equipment, engineering field networks PLC controller and 3G wireless routers etc.

The monitoring center platform also includes the monitoring center data server with the monitoring center client connection’s, used for data after storage monitoring center platform analysis and processing by evaluating and comparison of the threshold values.

The diagnosis and control includes: Device Management, equipment monitoring, equipment run statistical, map system, alarm management, report form, the permissions control, network management and machine maintenance records.

Remote Maintenance: The monitoring center platform for users to directly maintain the scene of SCR equipment wherein the PLC controller provides the maintenance channel links, making maintenance engineer maintenance channel set up through a network access monitoring center platform, remote debugging, modify, query site Heavy equipment related data online through the platform invoke PLC controller program. The monitoring center platform can receive real-time scene of remote equipment to upload data and display a variety of ways in the platform, the user can intuitively understand the operating state of the device. Maintenance Engineers’ quasi-real-time data can be judged site equipment operation status, effective monitoring equipment.

ESSENTIAL NOVEL FEATURE OF THE PRESENT INVENTION:

• Development of “Soft Intelligent Control Desk” based Wireless system for On-line Remote Diagnostics & Control of PLC & HMI for moving Stacker cum Reclaimer Machines.
• Control of moving SCR machines through “Intelligent Control Desk”.

• On-line HMI System in moving machines.

• Remote & Wireless access of critical RMHP data from SCR machines.

• A novel way that render provision for remote On-line diagnostics of other networked RMHP Automation system from SCR machine enabling significantly reducing electrical downtime.
• Remote & Wireless access of other PLCs & HMIs enabling better understanding of total RMHP area.

Although the foregoing description of the present invention has been shown and described with reference to particular embodiments and applications thereof, it has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the particular embodiments and applications disclosed. It will be apparent to those having ordinary skill in the art that a number of changes, modifications, variations, or alterations to the invention as described herein may be made, none of which depart from the spirit or scope of the present invention. The particular embodiments and applications were chosen and described to provide the best illustration of the principles of the invention and its practical

application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such changes, modifications, variations, and alterations should therefore be seen as being within the scope of the present invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.