A PLC program online procedure is as follow:
1. Open the project
2. Click on login
3. Click on No
4. PLC Login/Online window will appear
Creating a PLC backup in Code system for Messung Nexgen PLC
The procedure to make a PLC backup is as follow:
1. Open the code system software like CoDesys
V2.3
2. Recently opened PLC backup file will open
3. Click on file and close the program
4. Select on open
5. Open project from PLC section select on PLC
6. Configuration window will appear
7. Select on PLC model like Breakers Nexgen 5220 T1.4
8. Select on ok
9. Communication parameters window will appear select on update
10. Select on ok
11. Load project from PLC window will appear
12. Select on ok
13. Load project window will appear select on no all
14. Select on ok
15. The backup has now successfully been made
16. Click on file and select on save as ,Put the file name and save the project
Restoring a PLC backup in RSLogix5000 for Allen Bradley PLC
The PLC backup downloaded using the following process :
1.Browse to the PLC project file that needs to be downloaded
2. Open the file in RSLogix 5000
3. Select Download from the controller options dropdown
4. The Download window appears
5. Verify that the correct controller has been selected, by ensuring that the name, type, path, and serial number is correct
6. As a last check, make sure again that everyone involved is notified and that everything is safe
7. Click on the download button in the Download window
8. The ‘Downloading’ window appears, scrolling through all the different tags, programs, and routines being downloaded
9. After the download has successfully completed, the following popup appears
10. The controller was changed to program mode prior to the download and is still in program mode
11. Click on ‘Yes’, to change the controller to ‘Remote Run’
12. Save the project, go offline, and close the application
Creating a PLC backup in RSLogix5000 for Allen Bradley PLC
The procedure to make a PLC backup is as follow:
1. Open the PLC project file with the RSLogix 5000 application.
2. Go Online with the PLC, selected from the controller options dropdown
3. Click on File and select Save As
4. The ‘Save As’ Window appears
5. Browse to the folder where you want to save the file and give it a file name like ‘myPLC_Backup_CurrentDate’
6. Click on Save
7. A window pops up asking to upload tag values before saving
8. Select ‘Yes’. This will ensure that the latest values for the variables are loaded into the project. Where this matters, is where you may have parameters that are adjusted from an HMI or SCADA and you want these latest operator configurations to be backed up as well.
9. The backup has now successfully been made
10. Select ‘Go offline’ to disconnect from the controller
11. Close the application
Resistor and Type of Resistors
Resistor / Resistance: It is the property of a material which opposes the flow of electric current through it. Conductors have low resistance while insulators have very high resistance. It is measured in Ohms.
SV0435 Z INV. LOW VOLT DC LINK
This type of alarm occurs when DC voltage low coming from PSM ,DC Voltage not coming from PSM and DC link connection was loose
Remedy:
1. Check PSM should be ON
2. Check DC link voltage should be get 275 Vdc
3. Check DC link for loose connection
4. Check Stabilizer or Transformer input/Output voltage should be balanced
SV0444 X1 INV. COOLING FAN FAILURE ALARM
This type of alarm occurs when the servo drive cooling fan has gone bad.
Remedy:
1. Check alarm no 1 on the servo drive
2. Replace faulty drive other remove and re-insert servo drive cooling fan
9031 SPN 1 MOTOR LOCK OR V-SIG LOS ALARM
Problem: SPN1 motor lock or V-sig Los alarm
This type of alarm comes when there is single phasing in the spindle motor.
Remedy:
1. Check resistance of spindle motor should be balanced.
Example: Spindle motor resistance: -
RY-0.8 ohm,YB-0.8 ohm,BR-0.8 ohm.
3. Check input voltage of machine should be RY,YB & BR phase 200VAC.
In the picture above, the spindle motor wire is burnt due to SPN1 motor lock or V signal loss alarm occurred
PLC brand and Software name
| S.No. | PLC’s Brand | Developed Country | Software |
| 01 | AB PLC | United State | RS Logix (RS Logix 5, RS Logix 500 and RS Logix 5000) |
| 02 | Siemens PLC | Germany | Step 5- Micro wins Step 7- Simatic Manager |
| 03 | ABB PLC | Switzerland | Automation Builder AC010 AC500 |
| 04 | Delta PLC | Taiwan | WPL Soft ISP Soft |
| 05 | Schneider PLC | Europe | PL7 TwidoSuite ProWORX 32 |
| 06 | Mitsubishi PLC | Japan | Gx Developer Gx Works 2 MELSOFT series |
| 07 | Omron PLC | Japan | CX-One CX programmer |
| 08 | Hitachi PLC | Japan | EH-150 |
| 09 | General Electric PLC | United State | Durus |
| 10 | Honeywell PLC | United State | HRA |
| 11 | FATEK PLC | Taiwan | WinProladder |
| 12 | Bosch | Germany | Bosch Rexroth |
What is TIA Protal ?
Totally Integrated Automation Portal (TIA Portal). It gives you unrestricted access to the complete range of digitalized automation services, from digital planning to integrated engineering and transparent operation. With TIA Portal you gain valuable competitive advantages.
The Totally Integrated Automation Portal (TIA Portal), provides an engineering framework for implementing automation solutions in all industries around the globe. From designing, commissioning, operating, and maintaining to upgrading automation systems, the TIA Portal saves engineers time, cost, and effort. SIMATIC STEP 7 in the TIA Portal is the software for the configuration, programming, testing, and diagnosis of all modular and PC-based SIMATIC controllers, and includes a variety of user-friendly functions.
Software in TIA Portal
With TIA Portal you not only integrate the basic software (STEP 7, WinCC, SINAMICS Startdrive, SIMOCODE ES and SIMOTION SCOUT TIA), but you also benefit from additional functionalities provided by new options such as TIA Portal Multiuser Engineering and Power Management with SIMATIC Energy Suite via a single interface. That’s why TIA Portal offers everything you need for end-to-end engineering, both now and in the future.
Siemense 840D PLC General Reset Procedure
The following steps with the PLC start-up switch S4 will cause a PLC GENERAL RESET:
1. Turn to position “2” (STOP operating state)
PS LED lights up.
2. Turn to position “3” (MRES operating state, request general reset) and hold
in this position (for approx. 3 second) until the PS STOP LED lights up again.
PS LED goes out and comes on again.
3. Within 3 second, turn to the
STOP-MRES-STOP (“2”–“3”–“2”) positions
PS LED PS first flashes at approx. 2 Hz and then lights up again
PF LED lights up
4. Once the PS and PF LEDs are lit, turn the switch S4 to position “0”
The PS and PF LEDs goes out and the PR LED (green) lights up
A general reset of the PLC is complete. It is now in cyclical mode.
CNC Machine Spindle
Spindles are electrically or air-powered devices that come in numerous sizes. Typically, there is a shaft that holds the tool together, a motor, and a taper used to control various tools. Then, the spindle rotates on an axis. The axis is controlled by commands coming from either a person or a computer.
Spindle is a rotating shaft with a fixture for holding a tool (in the case of a milling, grinding, or drilling spindle) or a workpiece (in the case of a turning spindle). The spindle shaft serves as a support, a positioner, and a rotary drive for the tool or workpiece.
Varieties of spindles include grinding spindles, electric spindles, machine tool spindles, low-speed spindles, high speed spindles.
CNC Machine Spindle
CNC Machine Spindle Design
CNC Machine internal design show in Picture above
Resistance, Inductor,Capacitor
1.Resistor / Resistance: It is the property of a material which opposes the flow of electric current through it. Conductors have low resistance while insulators have very high resistance. It is measured in Ohms
2.Inductor / Inductance: It is the property of a coil to resist any change in electric current flowing through it. Self inductance is caused when a coil resists the current change through itself. Mutual inductance occurs when a secondary coil opposes current change in a primary coil. Inductance is measured in Henry.
3.Capacitor / Capacitance: The amount of charge that can be stored inside a capacitor at a given voltage is called Capacitance. It gets charged when charges are forced into the positive (or upper) plate of the capacitor due to emf. Similarly, it discharged when charges are forcefully pulled out of the capacitor. Capacitance is measured in Farad.
AC and DC
Electricity flows in two ways: either in an alternating current (AC) or in a direct current (DC). Electricity or "current" is nothing but the movement of electrons through a conductor, like a wire. The difference between AC and DC lies in the direction in which the electrons flow. In DC, the electrons flow steadily in a single direction, or "forward." In AC, electrons keep switching directions, sometimes going "forward" and then going "backward."Alternating current is the best way to transmit electricity over large distances.
Power Transformer
Power transformer is a static machine used for transforming power from one circuit to another without changing the frequency. As there is no rotating or moving parts, a transformer is classified as a static device. Transformer operates on an AC supply. Transformers operate based on the principle of mutual induction.
Grinding Machine
Grinding machine or grinder is an industrial power tool that uses an abrasive wheel for cutting or removing the material.
Grinding machine uses an abrasive product — usually a rotating wheel — to shape and finish a workpiece by removing metal and generating a surface within a given tolerance. A grinding wheel is made with abrasive grains bonded together. Each grain acts as a cutting tool, removing tiny chips from the workpiece.
Following are the types of grinding machines:
1.Bench Grinder: These types of grinding machines are fixed on a workbench or table. Gear or pulley is fitted in it. For rotating the big-size gears or pulley a handle is also fixed. It contains one or two grinding wheels. Edges of cutting tools can be made with this grinder. Provision can be made to operate these with power also.
2.Hand Grinder: This grinder is also fixed on the workbench or table. There is a provision of moving the grinding wheels with a level.
3.Pedestal Grinder: These types of grinding machines are operated with electric power. This is fitted on a pedestal frame separately on the ground. A grinder wheel is fitted each on both sides of the shaft of the electric motor.Tools rests are also provided with them. These are the most widely used in the workshops
4.Portable Grinder: This is a small grinder operated with electric power. It can be easily carried anywhere. Grinding can be done by holding it in hand. It is used for cleaning heavy welding jobs.
5.Flexible Grinder: Flexible shaft is fitted on the motor shaft with the help of a coupling. On one end of the shaft, a grinding wheel and handle are provided. Large jobs can be easily grinded with this grinder.
6.Precision Grinder: In this type of grinder, a movable spindle is fitted in the grinding wheel. This spindle is fitted on a table along with its motor. With this spindle, the grinding wheel can be turned in forward, backward, left, or right direction in running condition. Jobs of excellent finish and accuracy are grinded with it.
7.Surface Grinder: A surface grinder is a reciprocating grinding machine used for making flat surfaces on workpieces. It can form surfaces with greater precision.
8.Swing Frame Grinder: This grinder consists of a 2 or 3-meter long frame with a grinding wheel that is suspended at its center of gravity so that it can move freely.
Classification of Grinding Machine
Basically Grinding machine can be classified into two categories which are:
1.Non-Precision Grinding Machine: By this grinding machine, such materials are removed from workpieces that are rough such as materials made from casting, forging, etc.
Non Precision Grinders are :
1.Bench Grinder
2.Pedestal Grinder
3.Portable Grinder
4.Flexible Shaft Grinder
5.Swing Frame Grinder
2.Precision Grinding Machine: By this grinding machine, such materials are removed from workpieces that are soft and required precise surface finished.
Precision Grinders are:
Surface Grinder
1.Horizontal Spindle Reciprocating Table Horizontal Spindle Rotary Table
2.Vertical Spindle Reciprocating Table
3.Vertical Spindle Rotary Table
Cylindrical Grinder
1.External Cylindrical Grinder
2.Internal Cylindrical Grinder
3.Universal Cylindrical Grinder
4.Centerless Grinder
A.Tool and Cutter Grinder
B.Special Purpose Grinding Machine
Other Grinding Machine: It may be precision or non precision grinding machine.
1.Wet Grinding : In most of the grinding machines, there is a provision of a regular flow of coolant apparently on the workpiece where the wheel touches.
2.Dry Grinding : There is no arrangement of coolant system with the grinding machine and the workpiece is finished on that grinding machine then it is called dry grinding.
Grinding Defects
There are the following grinding defects found during the grinding operation.
1.Overheated Spots
2.Chatter Marks
3.Rapid wear of the Wheel
Causes of Overheated Spots
The excess wheel speed and feed.
Wheel in glazing condition.
Not using enough coolant.
Remedies of Overheated Spots
Use the right speed and feed.
Dress the wheel.
Use sufficient coolant
Causes of Chatter Marks
Wheel not mounted properly.
Slackness in the spindle.
Wheel unbalanced.
Not clamping properly job.
Excess cut depth for the machine.
Remedies of Chatter Marks
Mount the wheel correctly.
Remove slackness of spindle.
Balance the wheel.
Clamp the job properly.
Use the correct cut depth.
Causes of Rapid Wear of the Wheel
Wheel too soft.
Grinding wheel speed is less than the permissible speed.
Remedies Rapid Wear of the Wheel
Use the correct grade of the wheel.
Increase the wheel speed to the approved speed.
Adjustable Spanner
Adjustable spanner is an open-ended wrench with a moveable jaw. Its function is the same as any regular spanner to grip fasteners, such as nuts and bolts.
Clamp and Types of Clamp
Clamp: Device designed to bind or constrict or to press two or more parts together so as to hold them firmly.
Any of various devices used to join, grip, support, or compress mechanical or structural parts that can be brought together, usually by a screw, to grip something.
Production and Types of Production
What is production?
Production is a process of value addition, which is developed to transform a set of input elements like man, raw material, capital, energy, information into finished products and services in proper quality and quantity.
“Production is the organised activity of transforming resources into finished products in the form of goods and services; the objective of production is to satisfy the demand for such transformed resources”
What are 4 types of production?
1) Unit or Job type of production
2) Batch type of Production
3) Mass Production or Flow production
4) Continuous production or Process production
Punch and Types of Punch Tool
Punch is a device used to make an indentation or hole in a hard surface. Typically, they consist of a hard metal rod with a large flat “butt” at one end and a narrow tip at the other
When used, the narrower end is pointed against a target surface and the broad end is then struck with a hammer or mallet, causing the blunt force of the blow to be transmitted down the rod body and focused more sharply onto a small area.
Types of punches are as follows:
1. Centre punch
2.Prick punch
3.Solid punch
4.Transfer punch
5.Drive punch
6.Pin punch
7.Roll pin punch
8.Hollow punch
9.Dot punch
10.Letter stamps
11.Tablet punch
1024 PMM Axis Not Ready
This type of problem occurs when the PMM module is not healthy or not on.
Remedy:
1. Check PMM module fuse, The fuse should not be bad
2. Check control contector should be ON
9030 SPN 1 Overcurrent Pow Circuit Alarm
This type of alarm comes when there is a load on the spindle or one of the servo axis due to current increases and the driver goes to tripped
Remedy:
1.To resolve this issue, turn on the power again
2.Check Bearings and LM guide for jamming
Plier and Types of Pliers
The primary purpose of the tool known as pliers is to grip objects firmly. The objects can then be turned, bent, or otherwise manipulated. Pliers have parallel handles, a pivot where the handles join, and parallel jaws that grasp the object. Special-use pliers may have additional components and purposes, such as cutting pliers. Types of pliers include engineer's pliers for gripping metal, flat-nosed pliers for grasping smaller objects, electrician's pliers for gripping electrical wires, and round-nosed pliers for bending wire into loops. The most common are slip-joint and plumber's pliers, both with slip-joint adjustments to change the width of the jaw grip. In addition, locking pliers, sometimes known by the Vice-Grip brand name, are popular for firmly holding objects.
MTBF ( Mean Time Between Failures )
What is mean time between failures?
MTBF (mean time between failures) is the average time between repairable failures of a technology product. The metric is used to track both the availability and reliability of a product. The higher the time between failure, the more reliable the system.
MTBF calculation Formula:
MTBF Example :
Over a period of time the following information is available:
Total Production Time (PT): 1,240 minutes
Total Downtime (DT): 1.5 hours (watch the unit of measures)
Number of Failures (F): 25
Determine the MTBF:
The first step is to determine the Uptime (UT) which = PT - DT
Uptime (UT) = 1,240 minutes - 90 minutes = 1,150 minutes
MTBF = UT / F = 1,150 / 25 = 46 minutes
MTTR ( Mean Time To Repair )
What is MTTR?
Mean time to repair (MTTR) is a maintenance metric that measures the average time required to troubleshoot and repair failed equipment. It reflects how quickly an organization can respond to unplanned breakdowns and repair them.
MTTR calculates the period between the start of the incident and the moment the system returns to production.
Mean time to repair (MTTR): As described above, MTTR is the average time it takes for a failed system to be fixed and restored to full functionality. It is a relative measure, and therefore, depending on the system, could be measured in anything from minutes to days.
This takes into account the time to:
1.Notify technicians
2.Diagnose the issue
3.Fix the issue
4.Allow the equipment to cool down
5.Reassemble, align, and calibrate the asset
6.Set up, test, and start up the asset for production
Calculate MTTR by adding up the total time spent on repairs during any given period and then dividing that time by the number of repairs.
Mean Time To Repair = (Total downtime) / (number of failures)
MTTR Example :
Over a period of time the following information is available:
Total Production Time (PT): 1,240 minutes
Total Downtime (DT): 1.5 hours (watch the unit of measures)
Number of Failures (F): 25
Determine the MTTR:
MTTR = Total Downtime / Number of Failures = 90 minutes / 25 failures
MTTR = 3.6 minutes per failure
OEE ( Overall Equipment Effectiveness )
What is OEE?
Overall equipment effectiveness is a maintenance KPI that measures an asset’s level of productivity. OEE is a combination of three factors that tell you how efficient an asset is during the manufacturing process: asset availability, asset performance, and production quality.
1. Availability – How often does the asset function when needed?
2. Performance – How much does the asset produce?
3. Quality – How many high-quality items does the asset produce?
When an asset operates with an OEE of 100%, it means that every item it produces is without defect (quality), it is producing as fast as possible (performance), and it experiences no unplanned downtime (availability).
OEE Factors :
OEE Calcutation Formula :
OEE = Availability (A) × Performance (P) × Quality (Q)
Benchmarking OEE :
Ideal Availability 90% Normal 79%
Ideal Performance 95% Normal 80%
Ideal Quality 99.9% Normal 95%
Ideal OEE 85% Normal 60%
How is OEE used?
Overall equipment effectiveness is an indicator of how efficient the manufacturing process is. It can be used to identify underperforming assets and connect poor performance with one or more of the three main factors (availability, performance and quality). Once the source of the problem is pinpointed, the underlying issues can be investigated and improved.
Six Big Losses :
Maintenance and Types of Maintenance
What is Maintenance?
Maintenance, otherwise known as technical maintenance, refers to a set of processes and practices which aim to ensure the continuous and efficient operation of machinery, equipment, and other types of assets typically used in business. Diligence in implementing an effective maintenance program is essential to the successful performance and longevity of machinery, assets, facilities, and entire businesses.
Types of Maintenance :
There are different types of maintenance work, each designed for specific scenarios.
1. Breakdown Maintenance
2. Planned Maintenance
A. Preventive Maintenance
B. Predictive maintenance
C. Corrective Maintenance
3. Routine Maintenance
1. Breakdown Maintenance
Breakdown maintenance, sometimes called run-to-failure maintenance, occurs when an asset completely breaks down and needs repair to resume operation.
The breakdown maintenance is a type of maintenance that involves using a machine until it completely breaks down and then repairing it to working order.For example, this type of maintenance would occur if you wait until a machine stops working before fixing it.
Breakdown maintenance is triggered by either:
☆ A planned event, such as run-to-failure maintenance.
☆ An unplanned event, such as the need for reactive or corrective maintenance.
2. Planned Maintenance
Where routine maintenance may happen on a daily, weekly, or monthly basis, planned maintenance may be scheduled once per year or as needed. This is because planned maintenance is more time-consuming, expensive, and thorough—often requiring the services of a specialist. In the context of maintaining an air-conditioning unit, routine maintenance is taking out and washing the filters once per month, while planned maintenance is hiring an HVAC professional to check refrigerant levels, possible leaks, and measure airflow through the evaporator coil.
A. Preventive Maintenance
Preventive maintenance (PM) is the regular and routine maintenance of equipment and assets in order to keep them running and prevent any costly unplanned downtime from unexpected equipment failure.Preventive maintenance is the act of performing regularly scheduled maintenance activities to help prevent unexpected failures in the future. Put simply, it's about fixing things before they break.
Preventive maintenance (PM) is a simple and popular maintenance strategy. Preventive maintenance, also known as preventative maintenance, can help extend asset life, increase productivity, and ultimately decrease maintenance spending.
B. Predictive Maintenance
This maintenance type focuses on techniques used to determine the appropriate schedule for planned and corrective maintenance. Its primary goal is to predict, through a variety of testing methods, when a machine will start experiencing severe wear and tear so corrective maintenance can be scheduled without affecting productivity goals and before the machine breaks down.
C. Corrective Maintenance
Corrective maintenance is a maintenance task performed to identify, isolate, and rectify a fault so that the failed equipment, machine, or system can be restored to an operational condition within the tolerances or limits established for in-service operations.
Corrective maintenance covers maintenance tasks that are undertaken to identify, isolate and repair a fault in order to restore equipment, a machine or a system to an operational condition so it can perform its intended function.
Corrective maintenance is often associated to breakdowns or reactive maintenance and can include troubleshooting, disassembly, adjustment, repair, replacement and realignment.
3. Routine Maintenance
This type of maintenance, also referred to as preventive maintenance, is implemented on a fixed schedule and typically includes activities such as inspecting, cleaning, washing, replacing, and checking. It is typically performed in the downtime between shifts or on weekends to avoid affecting productivity goals. Routine maintenance has two objectives; to identify existing issues so they can be corrected ASAP and to prevent possible issues from becoming a reality through consistent care.
SV0368 B axis Serial data error alarm
This type of problem occurs whenever the B axis encoder or encoder cable is damaged or not conducted.
Remedy:
Check the B axis encoder cable is properly connected.
701 Over Heat Fan Motor Alarm
This type of problem occurs when the HMI back side cooling fan is not running.
Remedy:
Check the cooling fan of NC controller is it bad or correct if it is bad just replace it.
Note:
The cooling fan will be found on the back side of the HMI.
Cooling fan show in Picture above
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