The implementation of SCADA system for Beneficiati

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Implementation of SCADA system for Beneficiation Production Based on iFix

Abstract: This paper expounds the design requirements of HMI in Beneficiation control system, and determines to choose iFIX configuration software as the design of HMI. The HMI implementation method of SCADA system is introduced in detail. The practice shows that iFIX makes the whole automation system more flexible and reliable. The selection of iFIX greatly improves the return on investment and reduces the production cost of Hafei, Dong'an and other large industrial manufacturing enterprises in making mechanical component models

key words: iFIX, SCADA, PLC, man-machine interface

with the development of technology and the improvement of management requirements and the requirements of energy conservation and consumption reduction, it is necessary to improve the automation level of Beneficiation Production, realize the integration of management and control, and realize comprehensive digital management. In order to meet the above requirements, we must first realize the functions of on-site data collection and process monitoring of mineral processing, and then realize the centralized control and monitoring function, and then realize the real-time monitoring information system

this paper takes the beneficiation production process of a company as an example, based on the construction of a reliable, convenient and flexible monitoring system and the tensile properties of high molecular polymers: when used as materials, high molecular polymers are required to have the necessary mechanical property data acquisition system, and iFIX configuration software is selected to realize the monitoring in the production process. The following mainly introduces the control requirements of a beneficiation automation system, the characteristics of iFIX configuration software and the realization of SCADA system

1 selection of configuration software in SCADA system

1.1 system overview

beneficiation process includes: medium crushing, fine crushing, grinding, classification, flotation and other main and auxiliary processes. According to the requirements of process flow and distributed control theory, PLC control stations are set up in medium crushing, fine crushing, grinding, circulating water, etc., and centralized monitoring center is set up in the central control room. The characteristic of the system is that the monitoring center exchanges data with each sub control station through the network. Each sub control station independently controls all the controlled equipment of the process link according to the control program. When the system network is interrupted, the operation of the sub control station will not be affected, or when a sub control station fails, the operation of other sub control stations will not be affected. The system has high safety and reliability

1.2 control requirements

according to the characteristics of the system and the operation process, the following requirements are put forward for the configuration software

· the configuration screen is designed according to the system control structure diagram to reflect the whole process flow

· the picture is clear and lifelike, with dynamic effect during operation, and reflects the working condition of the equipment with color changes; The change of analog quantity is reflected by numerical value, curve or bar graph, and the alarm state is warned by more prominent color change and sound

· the picture design is carried out layer by layer according to the main picture nested sub picture form

· all operation data can be stored, and historical data can be backed up to other storage media regularly

· data can be displayed with real-time trend chart and historical trend chart

· security classification, different types of operators have different operation levels, and different operators have different operation passwords

· process parameters need ordinary changes and are easy to change

· be able to integrate controllers and instruments of different protocols into a complete system

· SCADA system needs to be integrated into the existing MIS system

· strong system compatibility, simple and convenient upgrade and transformation

1.3 selection of configuration software

according to the above requirements, compare the configuration software at home and abroad, and finally choose iFIX. The design of iFIX makes full use of the current most advanced software technology in the software kernel [1], and the package team forms a non-ferrous metal new material R & D and technology development team with distinctive characteristics and obvious advantages. The advantages include Microsoft's VBA, OPC, ODBC, ADO, ActiveX controls, com/dcom, which use an object-oriented framework. IFIX can implement high-performance automation solutions, and make the maintenance, upgrade and expansion of the system more convenient. The following are some advanced technical features of iFIX:

· powerful plug and play solution technology

· component object structure

· integrated development environment workspace TM

· VBA (Visual Basic for application) script

· high pass OPC (OLE for process control) technology

· enhanced safety and reliability, powerful redundancy function

· powerful graphic function, alarm function and historical data function

· customized expert guides, function buttons and recipe functions

· powerful network function, real distributed network structure

· unparalleled openness paves the way for the future upgrading of the system

2 system hardware

in the beneficiation production process, the CS series products of OMRON company are selected for the PLC of the medium crushing and fine crushing field control station, while the S7-300 series products of Siemens company are selected for the PLC of the field control station of the grinding and circulating water system. Some instruments need to communicate with the system through OPC. In the whole system, the information exchange between computer and OMRON PLC is carried out through control link, the information exchange between computer and Siemens PLC is carried out through PROFIBUS, and some instruments need to communicate with the system through OPC. In the implementation of this system, the SCADA system adopts a server to work and another hot backup to realize redundancy. By adopting this structure, the reliability and stability of the system have been greatly improved. In addition, the system also has a terminal server and several clients. Its structure is shown in Figure 1

Figure 1 system hardware structure diagram

scada server is mainly responsible for obtaining data from PLC, and users can remotely log in to iFIX terminal server through client to monitor or control the site. Remote users can dial into VPN through Internet. Through remote desktop connection (RDC) (Windows XP and Windows Server 2003), remote terminals can connect and access iFIX on the terminal server through ie5.0 or higher browser, and the client computer connecting to the server does not need to have the processing ability necessary for normal iFIX, It is convenient for the client to run on the platform from Win95 to Windows Server 2003

3 specific implementation of SCADA system based on iFix

3.1 communication with underlying PLC

after the SCADA server is started, a process database will be loaded, which receives data from PLC. Therefore, the required database must be established in iFIX to correspond to the data in PLC. The on-site data is transferred to the image table, and then scanned, alarmed, and the control program is transmitted to the process database. In this way, the internal database access function can be used to get data in the configuration application. IFIX can communicate with most PLC and DCS, and can communicate with any controller and instrument supporting OPC through OPC

3.2 human machine interface

after collecting field data in the process database, you can use iFIX to create a dynamic picture, so as to provide intuitive production process, necessary alarm prompts and some production data for monitoring, operation and management personnel. The beneficiation and crushing production is divided into the following main parts according to the distribution area of the measuring points: ore drawing machine, medium crusher, fine crusher, belt group, etc. IFIX provides a rich set of symbols, which can visually display the production status and various required data through the human-machine interface. It can be seen from Figure 2 that the man-machine interface configured with iFIX has the characteristics of clear and lifelike pictures, and the data can be displayed with real-time trend chart and historical trend chart; The picture has a dynamic effect during operation, which reflects the working condition of the equipment with the change of color, the change of analog quantity with the change of value, curve or bar graph, and the alarm state is warned with more prominent color change and sound

Figure 2 human machine interface of broken part of iFIX configuration

3.3 alarm realization

especially for some sensitive data, such as level and frequency, it needs to be strictly controlled within certain range. At this time, the upper limit, lower limit, upper limit and lower limit can be set through the data block to realize real-time alarm. Once the collected data exceeds the range, the monitoring or management personnel can be reminded by the buzzer and the flashing of the alarm color. Users can also use iFIX's alarm database to view previous alarms. IFIX provides the function of allocating alarm areas, and managers can create alarm areas as needed (iFIX itself provides 16 default alarm areas, from a to p respectively), so that once a situation occurs in any area, it can be very intuitive and clearly reflected

3.4 historical data and its trend chart

monitoring and management personnel often need to analyze various problems that may occur in the production of products through historical data, such as tracking and analyzing the production process. IFIX provides powerful support in this regard. Start "history definition" to define the acquisition group of SCADA nodes (including local nodes and remote nodes). Each collection group stores the tag name of each collection point required by the manager. After setting, you can start "historical data collection" in "task control". During the collection of historical data, you can also check whether there is data overload in "task control". If overload occurs, it indicates that the speed set in the mining group does not match, which will lead to the loss of some data block values. If overload occurs repeatedly, it may indicate that the phase of the acquisition group does not match and needs to be adjusted to reduce the occurrence of overload

in this system, the historical curve query interface shown in Figure 3 is developed with VBA. This tree structure can directly query the historical data of each variable. On this interface, the setting of the historical pen and the data scrolling buttons are also added

Figure 3 historical curve interface

3.5 implementation of formula

in the actual production process, the formula is often used, which can greatly improve the production efficiency. IFIX comes with a formulator, which provides functions such as generating, modifying, deleting, loading and downloading recipes

3.6 connection with database

ifix can provide historical data query, but managers often need to save data for months or even years, so they need to use a special database to save historical data. Moreover, mining companies need to integrate the SCADA system into the original information management system. The information management system adopts MS SQL Server 2000 database, so ODBC of iFIX is needed to access the data source

through ODBC, SCADA system can be seamlessly integrated into the information management system, where managers can understand the production situation and achieve the integration of management and control

4 conclusion

this system has good stability due to the redundant structure of SCADA. IFIX configuration software provides an intuitive dynamic picture, which is very clear and easy to understand. The application in the concentrator distributed control system fully reflects the powerful configuration function and networking function of ifixhi/scada software. Its open architecture facilitates the integration of other third-party components, and customizes the customized system environment. These powerful functions reduce the implementation time of engineering design, simplify the upgrading and maintenance of the system, and enable the seamless integration of iFIX and other third-party applications, significantly improving productivity


[1] intelligence iFIX quick start [z] GE Fanuc automation 2005.9:

[2] intelligence iFIX network configuration guide [z] GE Fanuc automation 2004.6:

[3] intelligence iFIX training manual [z] GE Fanuc automation 200 automatic switching between control rings 1.12: (end)