Pretoria-based systems integrator, AST, recently finished commissioning a system for Iscor Vanderbijlpark. It included the supply and commissioning of products and software for the mobile coke oven pusher cars at the Vaal Triangle site.
Throughput Technologies supplied eight ProSoft Ethernet RadioLink Switches, to allow for the communication from a central Rockwell ControlLogix PLC to seven SLC500 PLCs, each of which was installed on one of the seven pusher cars. Throughput Technologies also supplied a ProSoft Modbus module for the ControlLogix PLC to allow it to communicate data to an existing Telemecanique PLC.
The radio on the left communicates with all the radios on the pusher cars
In addition, On Time Networks' multiport Ethernet switches (again supplied by Throughput Technologies) were used to create links to additional Ethernet-based equipment on the pusher cars.
Werner Peters of Iscor explains the functionality of the system:
"The Master PLC receives a pushing and charging schedule of approximately 127 cycles from the Model Server. These cycles determine which oven to push or level (which happens during charging) and at what time. A new schedule is then transmitted to one of the seven pusher car PLCs that operates on the battery the schedule belongs to. Should a pusher car be positioned in front of the correct oven, and the time is equal to or greater than the desired pushing time, the door removal interlock is released and the operator can operate the pusher.
The pusher beam has two limit switches, mounted in the home and extended positions. The pushing cycle is not complete until the extended limit switch has been made. A signal is then sent to the Model Server to inform it that the pushing cycle is complete.
The leveller beam has only one limit switch, mounted in the home position. The levelling cycle is complete if the leveller is moved from and returns to the home position. A signal is then sent to the Model Server to inform it that the levelling cycle is complete.
During a pushing cycle a pushing resistance profile is recorded and stored. Once a cycle is completed, (after both pushing and levelling), the pusher machine PLC will inform the Model Server that the new data may be read from the pusher PLC. After the Model Server has read the new data it notifies the pusher machine PLC. If this is not done within a defined time-out period a failure handling procedure takes care of the buffering of data. After re-establishing communication, all data is read by the Model Server.
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