Abstract: This article introduces the application of PLCs from the German company VIPA in the control system of electroslag furnaces in the metallurgical industry. As a control system compatible with Siemens PLCs, VIPA's products are highly competitive, offering not only Siemens compatibility but also additional, highly useful functions, greatly enhancing their cost-effectiveness.
Keywords: electroslag furnace; VIPAPLC; Profibus; cost-effectiveness
1. Introduction
Siemens control products are widely used in the metallurgical industry. Our company has gradually introduced high-performance, cost-effective products from the German company VIPA, which are fully compatible with Siemens products, into our metallurgical projects. This has yielded excellent results and enhanced our competitiveness in undertaking projects.
2 System Composition
In the PLC control system of a certain electroslag furnace, we used the VIPA 300S series control system from Germany, whose main configuration is as follows:
1) One VIPA314-6CG03 is used as a CPU module;
2) Each VIPA300S CPU has an Ethernet communication interface, which functions similarly to the CP-343-1EX11 and can be directly connected to an industrial computer.
3) Each VIPA300S CPU has a configurable RS485 communication interface for communicating with four Xiamen Yudian temperature controllers.
4) Due to process design requirements, the PLCI/O modules need to be placed on two separate guide rails, so a second rack was added using Siemens IM365;
5) One remote Profibus-DP slave station, using a VIPA353-1DP01 interface module;
6) The two rotary encoders are directly connected to the counter interface built into the CPU to calculate the position of the electrodes.
7) Two Siemens DC speed controllers 6R7018 are used to control the slow-speed motor.
8) Two ABB frequency converters are used to control the rotation of the two arms.
The system structure block diagram is shown in Figure 1.
Figure 1 System structure block diagram
The system has been in production for over a year, meeting design requirements and demonstrating stability and reliability. The entire control system, from the controller to the remote station, utilizes PLC products from VIPA.
2.1 Main Control Station (Rack 1):
The VIPA314-6CG03 CPU was selected, employing VIPASPEED7 technology, which is currently the fastest PLC based on Step7 programming. It is compatible with Siemens (6ES7314-6CG03-0AB0V2.0), but features expanded 8 DIO, an Ethernet interface module, and a 485PtP interface. This VIPA model, with its Profibus-DP interface and RS485PtP interface, is particularly suitable for this project. Two VIPA322-1BH00 digital output modules from the VIPA300V series were also connected. Their arrangement is shown in Figure 2.
Figure 2
2.22. Main Control Station (Rack 2):
The second rack is expanded using Siemens IM365, while other modules are VIPA modules. Since VIPA CPUs can directly power 32 I/O modules, VIPA does not offer products similar to the Siemens IM365. Due to process design requirements, the I/O modules must be mounted on two separate guide rails, arranged as shown in Figure 3.
Figure 3
2.2 Profibus-DP Slave (Remote I/O Station):
The remote I/O uses the VIPA353-1DP01 interface module from VIPA, and inserts six modules from VIPA's 300V series. Its usage is similar to the Siemens ET200M, but requires installing the dedicated GSD file provided by VIPA for Profibus configuration. Each remote station can have a maximum of 32 modules configured as shown in the diagram below:
Figure 4
2.3 Programming and Configuration
The VIPA PLC can be configured and programmed using Siemens Step7-V5.3, and its usage is completely consistent with Siemens. The hardware configuration is shown in Figure 5.
Figure 5 System hardware configuration diagram
2.41 industrial PCs were used as engineering workstations:
One Advantech industrial PC serves as the engineering workstation. Since the VIPA300S CPU has a built-in Ethernet interface, the engineering workstation communicates with the PLC via Ethernet. This port also allows for PLC configuration and programming (PG/PC), eliminating the need for an MPI adapter for programming. The engineering workstation software uses Siemens PRODAVE 6 or the free Libnodave to communicate with the PLC via TCP/IP. (See Figure 6.)
Figure 6
3 Application Experience
Using VIPA PLCs, the programming platform uses Siemens' STEP7-V5.3 or later, and the programming method is completely consistent with Siemens PLCs. To connect VIPA's remote modules to the DP bus, the GSD file provided by VIPA must be installed; its usage is similar to that of Siemens remote stations. The VIPA 300SCPU has a built-in CP-343-1 Ethernet interface, uses SPEED7 technology, and has a faster operating speed than the Siemens 400, offering high cost-effectiveness. Furthermore, PLC programming and hardware configuration can be performed directly via the Ethernet port, making it very convenient to use.
About the Author
Li Zhounan is a professor-level senior engineer at Xi'an Aoxin Technology Co., Ltd.
