Hello engineers and technicians of PLCS.net! I am seeking your expertise and guidance for a project I am working on after graduating from University. The project involves creating a physical, simulated batch process to enhance my skills in control technologies and to bolster my portfolio for potential employers. The batch process concept consists of a compact mixing station using tanks ranging from 5-15 gallons. The system allows for the creation of RED, BLUE, and PURPLE products by mixing water, red dye, and blue dye in varying proportions. The finished product is then sent to a recycling tank for dye removal using a chlorine/bleach solution. To control this process, a Siemens S7 PLC/IPC will be utilized. The system will include solenoid valves for controlling ingredient input, ultrasonic level sensors for measuring tank levels, and a touch-screen HMI for user interaction. I have a few concerns regarding the project, such as the use of solenoid valves for control, the safety of using chlorine for dye removal, the best method for filtering out chlorine from the water, and the overall feasibility of the project. Any feedback or advice on improving the design and functionality of the system would be greatly appreciated. I aim to create a visually appealing and educational model that can be used for demonstrations and presentations. Your input will be invaluable in ensuring the success of this project. Thank you for your assistance!
Welcome to our website. Unfortunately, we do not have the necessary software to assist you with Seimens. However, it's great to see that you have embarked on such an intriguing project.
When considering how to control the input to a mixing vessel, utilizing solenoid valves may be the most effective method. Gravity feeding ingredients may seem like a good idea, but it can lead to inaccuracies in the mixing process. The accuracy of the mix will depend on your desired precision level. While adding liquids like water and liquid concentrates may work well, achieving consistent control over Parts Per Million in the water can be challenging. Using dry powder dye can present even more difficulties, as it tends to clump and disrupt the gravity feeding process. To maintain a more consistent feed rate, consider using a large-diameter, low-height feed tank positioned at the highest point possible. This can help reduce the impact of varying tank levels on the feed pressure. Keep in mind the potential for toxic byproducts, such as chlorine gas, when mixing chlorine with water/dye. In general, using distilled water instead of city water can help prevent premature fading of colors. Proper ventilation, such as operating under a lab hood with an exhaust fan, can help mitigate the risks associated with chlorine fumes. Operating in a closed tank system can also help minimize exposure to harmful gases.
One innovative solution is to purchase several color-sensitive photosensors with analog outputs. By setting a predetermined color level and adding dye into the mix tank until the color matches the set level, you can achieve precise control over the mixture. Although the photosensors may be a bit pricier, they will greatly enhance the accuracy of the blending process.
Lancie1 suggested an interesting method that involves purchasing color-sensitive photosensors with analog outputs to achieve precise control over the mixture. By setting a color level and adding dye into the mix tank until the desired color is attained, you can ensure accurate results. While the photosensors may come at a slightly higher cost, they offer superior control compared to other methods. I greatly appreciate the recommendation and will look into using color-sensitive photosensors for my project. Additionally, thank you for your insightful suggestions, Lancie1. Your input has been invaluable. In terms of dye selection, it is advisable to opt for liquid solutions or tablets instead of dry powder. Dry powder dye can lead to inconsistent feeding due to clumping and sticking issues. To maintain a steady feed rate, consider using a large-diameter low-height feed tank positioned vertically to minimize pressure variations as the tank level decreases. I am considering implementing an automated system for feeding dye tablets into my ingredient tank, along with adding water as needed. However, I am still exploring the mechanical aspects of this setup. Would using chlorine tablets be a viable option for removing dye from the final product, or should I stick to a liquid chlorine solution? I am concerned about the rapid dissipation of liquid chlorine at room temperature. Your thoughts on the filtration process would also be appreciated, Lancie1. Thank you once again for your thorough solutions to my challenges. I am committed to exploring all possible angles to ensure the success of my project.
Considering an upgrade to the system, but further evaluation is needed to source the necessary mechanical components. One potential idea is to create a tablet dispenser using a cylinder configuration, with a solenoid-operated pusher to release tablets individually. The drawback of this method is the limitation on color variations compared to using liquid dye. Consideration is also given to using chlorine tablets to eliminate the dye component from the final product, which may present a more feasible alternative over a chlorine liquid solution. Liquid mixing is easier, requiring no additional equipment, unlike tablets which may need a stirrer. Utilizing a home water pitcher filter, such as the Pur filter, could effectively remove chlorine from water. Additionally, integrating color-sensitive photoelectric sensors, like the Allen Bradley Colorsight 45CLR, could enhance color detection capabilities within the system. Further research is needed on the sensors to determine compatibility with the current PLC setup.
This sounds like a fascinating project you're embarking on! Regarding your concerns: one, solenoid valves should work fine for the level of control you need, but make sure you include an override or manual control as a safety measure. Two, if chlorine is used safely and cautiously, it should function well for dye removal. However, please take into account local regulations concerning its use and disposal. As for filtering out the chlorine, you might want to consider activated carbon filters, they're pretty efficient in removing chlorine from water. Finally, in terms of feasibility, it's indeed an ambitious project but with careful planning and execution, it's certainly achievable. Don't forget the importance of frequent testing and debugging during the assembly process. Best of luck!
Your project seems ambitious and well thought out! As someone who has worked on similar automation projects, I feel that your solenoid choice is appropriate though I would suggest considering servo-controlled valves if budget permits, as they offer better precision control. Regarding chlorine safety, ensure the workspace is well ventilated and preferably automate the dosing step to minimize human contact. As for removing chlorine from water, activated carbon filters work wonderfully. Overall, your project sounds feasible and quite impressive given your level of experience. My best advice would be to break it down into small manageable steps, starting from the most basic functionality and gradually adding complexity. Keep us updated and good luck!
Firstly, congratulations on such an ambitious post-graduation project! Your concern about using solenoid valves is valid; while they're great for binary on/off control, they might not offer the precision you need when mixing specific proportions of dye. You might want to consider looking into proportional control valves as an alternative. Regarding your safety concerns about using chlorine, it is indeed a hazardous chemical. Just ensure your workspace is well-ventilated and you're employing proper Safety Data Sheet (SDS) practices. For eliminating chlorine from the water, activated charcoal filtration could work, as it effectively removes chlorine by adsorption. Lastly, in terms of the overall feasibility, it sounds quite manageable for someone with your skills and enthusiasm. Just remember to work in manageable chunks, starting with a single process loop (like Red production) before branching out. Good luck with your project!
Hello and congratulations on your project, it sounds like a fantastic way to apply your learning and enhance your portfolio. Regarding your concerns, solenoid valves seem to be a great fit for the job due to their reliability and precise control. For the safety issue, it's critical to ensure that your chlorine/bleach concentration is low enough to be safe while effectively removing the dye. A pH-neutral bleach solution would be less corrosive and safer to handle. As for filtering out chlorine from the water, activated carbon filtration systems are often used to remove chlorine, and they are quite cost-effective. Overall, the project seems feasible and definitely a good learning experience. A word of advice: keep the design simple and focus on the control logic, which is what potential employers will look at. Keep us posted on your progress, I'm excited to see how it comes together!
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Answer: - The project involves a compact mixing station with tanks ranging from 5-15 gallons, solenoid valves for ingredient control, ultrasonic level sensors for tank level measurement, and a touch-screen HMI for user interaction.
Answer: - The batch process is controlled using a Siemens S7 PLC/IPC for automation and sequencing of operations.
Answer: - The system allows for the creation of RED, BLUE, and PURPLE products by mixing water, red dye, and blue dye in varying proportions.
Answer: - Chlorine is used for dye removal in the recycling tank, and safety precautions must be considered during handling and operation.
Answer: - The best method for filtering out chlorine from the water should be determined based on safety and efficiency considerations tailored to the specific project requirements.
Answer: - The aim of the project is to create a visually appealing and educational model that can be used for demonstrations and presentations to enhance skills in control technologies and bolster the portfolio for potential employers.
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