Design and Implementation of an Automobile Fuel Tank Rolling

Valve Assembly and Detection System

Zhiming Wang

1, a

, Qi Hua

1, b

, Wangwei Ye

and Sijia Gong

School of Mechatronic Engineering and Automation, Shanghai University, Shanghai 200072, China

Keywords: PLC, MCGS, Labview, automotive test.

Abstract: At present, the structure of the reversing valve mainly used in the automobile industry is special, and the

assembly thereof is basically in the manual stage, and the production efficiency of the reversing valve is

generally low. This paper mainly designs a set of automatic assembly detection system based on PLC

control system. It uses MCGS touch screen and upper computer Labview as a friendly human-computer

interaction interface. Through the coordination of various parts, the purpose of automated assembly and

testing is achieved. To solve the production capacity of the product. The test results show that the system

can complete the automatic assembly and flow performance detection of the reversing valve stably and

efficiently.

1 INTRODUCTION

Automobile fuel systems are generally equipped

with rollover valves. In order to ensure a constant

pressure difference between the fuel tank and the

inside of the fuel tank, the fuel tank is prevented

from sucking, the fuel tank is prevented from tilting,

or a fuel leak occurs when the vehicle accident is

turned over (Zhiming Wang, 2007). Due to the

special assembly process of the rollover valve, the

production is still in the manual assembly stage. In

addition, the air tightness and the flow rate are

detected after the manual assembly, which results in

low production efficiency of the rollover valve.

This paper is mainly for a rollover valve.

According to the assembly characteristics of the

valve and assembly requirements, the overall design

of the system structure is carried out by using

relevant advanced technology. Based on the overall

structure of the machine, the main control system

was determined with the assembly process as the

guide. Finally, a set of automatic assembly detection

system based on Siemens PLC, MCGS touch screen

and upper computer Labview was designed. The

system includes six stations for discharging,

assembling and testing. The valve flow and air

tightness are tested during assembly.

2 ROLLOVER VALVE

ASSEMBLY SYSTEM

STRUCTURE DESIGN

Combined with the characteristics of the various

components of the oil valve, the appropriate

assembly process is matched. Considering the

simultaneous assembly and detection during the

assembly process, the rotary indexing operation

mode is determined, and the disk type six-station

assembly test structure is finally designed(Zhiming

Wang, 2007; Lin Min, 2018). With the cooperation

of the upper and lower position machines, the

rhythm compact periodic action is realized, the

operation is stable, the index is accurate, and the

efficiency is excellent, which can meet the

requirements of actual production (Zhao Dandan,

2018). The automatic assembly machine layout is

shown in Figure 1.

Wang, Z., Hua, Q., Ye, W. and Gong, S.

Design and Implementation of an Automobile Fuel Tank Rolling Valve Assembly and Detection System.

DOI: 10.5220/0008850700320037

In Proceedings of 5th International Conference on Vehicle, Mechanical and Electrical Engineering (ICVMEE 2019), pages 32-37

ISBN: 978-989-758-412-1

Fig 1. Automatic assembly system layout.

Fig. 2 Equipment control mode diagram.

3 CONTROL SYSTEM DESIGN

The disc type rotary automatic assembly test system

is mainly coordinated by the PLC main control unit,

servo motor, electric cylinder, cylinder, flow meter

and other execution units to realize automatic

assembly and measurement of the product. The

bottom control of the rollover valve assembly is

completed by Siemens PLC. The MCGS touch

screen realizes the parameter setting and status

monitoring of the assembly. The upper machine

Labview realizes the display of the real-time

measurement curve of the oil valve and the

processing of the test data. Equipment control mode

diagram is shown in Figure 2.

Design and Implementation of an Automobile Fuel Tank Rolling Valve Assembly and Detection System

3.1 Section Headings

PLC is widely used in modern control systems due

to its small size, low cost, high reliability and strong

anti-interference ability. The system uses Siemens

S7-1200 series CPU, combined with I/O expansion

module, analog module, etc., and is programmed

with TIA PORTAL V14. The control system mainly

includes PLC controller, servo motor, electric

cylinder, cylinder and other actuators, and each part

is coordinated with each other to form an organic

whole, realizing automatic assembly and detection

(Suli Zhong, 2017).

3.1.1 Main Program Module

The main program module mainly includes a calling

program segment for six FC modules, an Ethernet

communication program segment of the upper

computer Labview, an error code program segment,

an emergency stop and an automatic interlocking

program segment, and a data transfer processing

program segment of the upper computer. Production

ratio and timing block, alarm-light-discharge

reminder. The FC1-FC6 modules respectively

correspond to the logic programming of six stations

(Wu Jianlong, 2018). The FC module contains the

main program, manual program, single-step program,

single-station program, automatic program and clear

automatic program of the station.

3.1.2 Hand Automatic Interlock and Process

Module

The module mainly includes program segments:

screen button interlock, hand automatic interlock,

output relay, sensor shielding, data single rotation,

time conversion block and alarm.

3.1.3 IAI Electric Cylinder Servo Drive

Module

The module mainly includes a program segment:

reading the position of the servo electric cylinder

and judging and calculating, finishing the writing

position information, basic control commands,

writing commands and positions (Zhao Dandan,

2018; Suli Zhong, 2017).

3.1.4 Sensor Conversion Module

The collected sensor data is processed, and then

logically programmed in the program, finally

achieving stable interaction with the machine, and

transmitting the required measurement data to the

host computer for display and saving.

3.2 Human-Computer Interaction Page

Design

The system adopts MCGS touch screen and upper

computer Labview as human-machine interface. The

touch screen mainly realizes operation and

monitoring of assembly process, realizes parameter

configuration of equipment, fault alarm and so on

(Wang Hongyi, 2017). The upper computer Labview

mainly realizes the display of product detection

curve and the processing of product quality

inspection data.

3.2.1 Main Program Module

The main interface mainly realizes the product

assembly status and data display. Basically contains

all the information about the product assembly.

Including production, the number and proportion of

qualified products or non-conforming products, real-

time test data of the product, assembly test time and

cycle, alarm display, product status display of each

station, including parameter setting, status

monitoring, manual operation, etc. Entrance.

3.2.2 Main Program Module

The parameter setting interface mainly sets the

parameters of each part of the system, including test

parameters, analog parameters, servo parameters,

delay parameters, I/O shielding, and function

shielding (Wu Jianlong, 2018). As shown in Figure

4 test parameter setting interface, the pressure, time

and flow parameters of the large and small flow test

are mainly set, and the pressure limit of different

stations is set.

Fig 3. Assembly system control module diagram

ICVMEE 2019 - 5th International Conference on Vehicle, Mechanical and Electrical Engineering

Fig 4. Human-computer interaction main interface.

Fig 5. Parameter setting interface.

Fig 6. Status monitoring interface.

Fig 7. Manual operation interface.

3.2.3 Main Program Module

The status monitoring interface is mainly used to

display the working status of each input and output

point in real time. The screen display is intuitive and

easy to understand, which facilitates the

maintenance and maintenance of the equipment,

making the human-machine interface more friendly.

3.2.4 Main Program Module

The manual operation interface includes operation

inlets of six stations, which can operate separately

for different stations. Each interface is independent

of each other, and an interlock mechanism is added

in the programming to prevent manual stations from

interfering with each other. As shown in Figure 7,

station 2, including manual operation, can perform

any action in the interface; single-step operation can

single-step the action of the station; single-station

operation can execute the entire process of the

station.

3.2.5 Main Program Module

The upper computer test interface mainly realizes

the display of test values and the preservation of test

data. The real-time flow curve of the three-station

and five-station is displayed in the interface, which

is intuitive and easy for the tester to observe. Each

station test data provides the status of each station

test. Save experimental data.

Design and Implementation of an Automobile Fuel Tank Rolling Valve Assembly and Detection System

Fig 8. PC test interface.

4 COMMUNICATION

4.1 Ethernet Communication between

the S7-1200 PLC and the Touch

Screen and the Host Computer

The S7-1200 integrates a PROFINET

communication port that supports Ethernet and

TCP/IP-based communication standards. Set the IP

address of the PLC and touch screen so that they are

in the same network segment, so that the touch

screen and the PLC are connected to the network

cable (Zhiming Wang, 2018). After the PLC

searches for an accessible device, it confirms that the

connection is completed and communicates through

the variables in the PLC. First check the optimized

block access of the data block in the PLC and then

generate the variables. When programming the touch

screen, simply import the tags and select the user-

defined global variables or elements in the global

data block in the S7-1200 PLC. The S7-1200PLC

and the host computer Labview are based on the

Modbus TCP communication protocol, and the

Modbus TCP server communicates via the

PROFINET connection (Bao Dewei, 2007). The

"MB_SERVER" instruction will process the

connection request from the Modbus TCP client,

receive and process the Modbus request and send a

response.

4.2 Communication between S7-1200

PLC and Servo Drive

The S7-1200PLC expands the CB1241RS485 signal

board to realize the communication function of the

S7-1200 master station (Bao Dewei, 2007). The

RS485-based serial port realizes free port

communication between the PLC master station and

the servo slave station (Zhiming Wang, 2018). Then

configure the port parameters, complete the

communication settings, and finally write the serial

communication program.

5 EXPERIMENTAL RESULT

According to the actual production situation, in the

case of normal continuous feeding, the system cycle

period is 36 seconds, the product can be assembled

according to the standard, and the flow performance

of the assembled product is stably detected, and the

performance curve is displayed on the screen of the

upper computer. The system moves smoothly and

the cycle is compact, which greatly shortens the

assembly cycle of the special product, and realizes

the measurement product performance during the

assembly process, further improves the product

completion efficiency, fully achieves the expected

goal, and all the functions of the system are running

normally during the system operation (Wu Jianlong,

2018), emergency stop, alarm, safety grating, etc.

ICVMEE 2019 - 5th International Conference on Vehicle, Mechanical and Electrical Engineering

make the system have good human-machine

performance.

6 CONCLUSION

This paper mainly designs an automatic assembly

detection system for automobile fuel tank turn-over

valve, which mainly includes mechanical structure

and control system.

This system uses PLC as the system controller,

and uses AC servo motor, servo electric cylinder,

cylinder and so on as the actuator. The system also

uses closed-loop control to ensure higher assembly

accuracy. Not only does Z take a variety of

protective measures on the mechanical design, but

also add logic protection in the software

programming of the control system to achieve dual

protection of the system. The system realizes the

automatic operation of the control process based on

the extremely stable stability and logic performance

of the PLC. The MCGS touch screen and the

Labview of the upper computer finally realize the

coordinated operation of each station.

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Design and Implementation of an Automobile Fuel Tank Rolling Valve Assembly and Detection System