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在企業(yè)搬遷工作中，原來在包裝崗位有兩臺其他品牌的小型 PLC在使用，分別控制堆垛崗位和封切熱縮崗位。目前該型號產(chǎn)品已經(jīng)被淘汰，而在搬遷后發(fā)現(xiàn)，PLC上電無反應(yīng)，必須要進(jìn)行更新?lián)Q代。
　　1　工藝原理
　　本包裝設(shè)備，完成對本廠建材產(chǎn)品的包裝，包裝材料使用PE 熱縮塑封膜。主要工藝步驟包括：①堆垛;②封切：對塑料膜進(jìn)行切斷和封口;③熱縮：使PE膜加熱收縮包裹產(chǎn)品。
　　2　方案選型
　　2.1 控制方案設(shè)計
　　針對本系統(tǒng)的特點，適合采用集成了IO點的小型PLC。而溫度可以單獨交給溫控表進(jìn)行控制，速度由變頻器進(jìn)行調(diào)節(jié)，為了提高系統(tǒng)操作性能，溫控表和變頻器與PLC進(jìn)行MODBUS通信，交換數(shù)據(jù)。同時，PLC通過網(wǎng)線連接至中控室上位機(jī)，完成數(shù)據(jù)采集、顯示和必要的操作。
　　2.2 PLC選型及IO表設(shè)計
　　根據(jù)現(xiàn)場設(shè)備匯總需要輸入點13個，輸出點12個，使用 S7-200 SMART系列的SR40型號CPU并設(shè)計IO表。
　　2.3 其它主要電氣設(shè)備選型
　　另外選擇了1臺安川V1000變頻器和2臺山武SDC36溫控表分別進(jìn)行速度和溫度的控制，它們都支持通過MODBUS通信協(xié)議與 S7-200 SMART進(jìn)行通信。
　　2.4 確定通訊方案
　　(1)上位機(jī)以太網(wǎng)通信方案本工廠使用的上位機(jī)為亞控公司生產(chǎn)的組態(tài)王上位機(jī)組態(tài)軟件，經(jīng)過查找發(fā)現(xiàn)組態(tài)王已經(jīng)更新了S7-200 SMART的驅(qū)動，驅(qū)動名稱：S7 TCP.DLL，驅(qū)動版本：60.1.24.30。
　　(2)MODBUS通訊方案安川V1000變頻器和山武SDC36溫控表具有非常相似的指令結(jié)構(gòu)，能夠方便地接入系統(tǒng)。
　其中讀取和寫入的功能碼分別是03H和10H。
　　3　編程與調(diào)試
　　3.1 IO控制程序編程與調(diào)試
　　塑封膜包裝線中堆垛和封切工序的動作最為復(fù)雜，而且各動作也存在著邏輯關(guān)系，為了準(zhǔn)確執(zhí)行各封切動作，采用步進(jìn)控制。其他的只采用普通的邏輯控制即可。
　　3.2 MODBUS通信程序編程與調(diào)試

INDRAMAT TDM1.4-050-300-W1-000 USPP TDM14050300W1000

ALLEN BRADLEY 150-A360NBD-C USPP 150A360NBDC

CONTROL TECHNIQUES 9500-8307 USPP 95008307

CONTROL TECHNIQUES 115DSA300T USPP 115DSA300T

RELIANCE ELECTRIC 61C-613 USPP 61C613

SIEMENS 6ES5-243-1AA11 USPP 6ES52431AA11

BOSCH SFA4023003000050 NSFP SFA4023003000050

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SIEMENS 6ES5 734-2BF00 -FS- 6ES57342BF00

SIEMENS S5 6ES5 454-7LA11 6ES54547LA11 Output Module

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SIEMENS ITE MOORE AUXILIARY SWITCH CONTACT BLOCK STY6-501-1B 3TB44/46/48/50

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AC Technology M14300B Inbligent Drive MC Series 30 HP

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8 MKS baratron 124A-11848, 2000 Torr Range, S141A, looks clean

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ALLEN BRADLEY 6185-EACABBZ USPP 6185EACABBZ

ALLEN BRADLEY 2711-T9C3 USPP 2711T9C3

INDUSTRIAL DEVICES B8962-FK1-AAAA-FF USPP B8962FK1AAAAFF

ZUMBACH ELECTRONIC ODAC-24-19CR USPP ODAC2419CR

YAMATAKE 80360141-011 USPP 80360141011

LOAD CONTROLS INC PPC-1 USPP PPC1

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SIEMENS S5 6ES5 308-3UA12 IM308A Interface Module

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RELEASE SuperMicro X9DRG-HF Motherboard FULL MFR

Texas Instruments 5TI-1023

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TV One C2-2375A CORIO2 CV/DVI/3G-SDI Converter

Siemens DCS Module 6DS1601-8AC in Box, Seal opened,

Modicon MM-FMP1-000

Schneider Modicon Subrack AS-HDTA-202

Schneider Modicon ASB883200 AS-B883-200 Thermocouple Input Module

Schneider Modicon AS-BFRQ-204 NSFP ASBFRQ204

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Schneider Modicon MOT202/AS-BMOT-202

Schneider Modicon H.S. Counter Module AS-B883-001 ASB883001

SCHNEIDER TELEMECANIQUE OTB1EODM9LP ETHERNET INTERFACE MODULE

Schneider Automation TSX-DET1612 16 Point Input Module TSX-DET-1612 TSXDET1612

PWR-C45-1000AC CATALYST 4500 1000W AC POWER SUPPLY

SIEMENS 6ES5451-4UA12 OUTPUT MODULE 6ES54514UA12

SIEMENS 6DD1611-0AF0 NSFP 6DD16110AF0

LUCENT Partner Plus Phone Communications System 103B9 Carrier w/ 5 Modules

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SIEMENS /MOORE 16167-1-3 SDM TERMINATION ASSEMBLY 1616713

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Allen Bradley Rockwell 2711-K10C20 Color HMI PanelView 1000

ABB S6H800BW

A06B-0148-B084#7075 FANUC SERVO MOTORS REMANUFACTURED

09-CPL1859-25, 3mm polyester, flexible printed curcuit

ORMEC GN3-40/2MI USPP GN3402MI

ALLEN BRADLEY 1771-DA FNFP 1771DA

ALLEN BRADLEY 1336S-B007-AN-EN4-GM1-HAP-L6 USPP 1336SB007ANEN4GM

GENERAL ELECTRIC DS200IMCPG1AEA USPP DS200IMCPG1AEA

TB WOODS WFC4015-0C USPP WFC40150C

SQUARE D 8660-MGO46 USPP 8660MGO46

CONTROL TECHNIQUES DD-150 USPP DD150

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Siemens Watchdog Module 6ES5 313-3AA12 SURPLUS Orig. Box No Paperwork

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Wago 750-553 4-CHANNEL ANALOG OUTPUT MODULE 0-20 mA

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Modicon AS-P451-622

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Schneider Modicon Extender Cable 6' AS-W801-006 warranty

Schneider Modicon AS-J878-000 MODEM MODULE ASJ878000

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REMAN Allen Bradley 1756-HSC /A ControlLogix High Speed Counter

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ProSoft MVI56-WA-PWP inRAx Wireless Communication Module 2.4 GHz

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Zaytran Parallel Gripper GPL-400-SM #32250

(R2-8) 1 BAILEY INIIT02 NET MODULE R2-8

MITSUBISHI A4U-CPU USPP A4UCPU

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GENERAL ELECTRIC 44A399751-G01 USPP 44A399751G01

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TEXAS INSTRUMENTS PLC 2223050-0003 USPP 22230500003

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Square D 8030 CRM-560

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Woodhead SST SST-PFB-PLC5 ProfiBus Coprocessor for Allen Bradley PLC5

SIEMENS 6ES7621-6BD01-0AE3 Membrane Keypad C7-621 ping Worldwide

Siemens TD200 6ES7272-0AA30-0YA1 Membrane keypad

Seco Q7002

Schneider Modicon AS-H827-209 Chassis ASH827209 F355

Schneider Modicon AS-B570-001 USPP ASB570001

Schneider Modicon BATTERY BACK UP LITHIUM AS5378-002

Schneider Modicon AS-E685-904

Schneider Modicon AS-B838-032/ASB838032 Output Module OFFERS ACCEPTED

Modicon 553 VIC 153 39 PFIS Operator Interface Computer 553VIC15339

SIEMENS ANALOG INPUT MODULE 6ES5 464-8MA21

Schneider Modicon Premium TSXPACC01 TSX PACC 01 Terminal Isolation Box NIB FS

SIEMENS MODULE DIGITAL OUTPUT 505-4516 5054516

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(3595) Siemens Operator Interface 6AV3572-2FM00 (3595)

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TIMKEN 82562 NSFP 82562

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Mercedes Benz Telephone Phone Control Unit Module Universal Handy Interface OEM

Xilinx Avnet Virtex-6 LX130T Evaluation Kit AES-V6EV-LX130T-G

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Siemens PC-PPI+ PLC ISO Cable 6ES7 901-3CB30-0XA0 NIB

Reliance 0-51865-1

Schneider Modicon AS-B239-001 ASB239001 High Speed Counter NIB

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Schneider Modicon AS-B804-016 Output Module 115Vac

Schneider Modicon AS-B248 10TO60 VDC 2-5A OUTPUT MODULE GOOD TAKEOUT

MODICON PANELMATE PLUS MM-PM15-414

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ACTERNA/WAVETEK/WILTEK 4202S GSM TEST SYSTEM

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8960 Series 10 Wireless Communications Test Set

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BAYSIDE PXY-236 USPP PXY236

AYDIN CONTROLS 9010CX-153-552-01-71-00 NSFP 9010CX1535520171

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ITE SIEMENS LMXD63B800 NSFP LMXD63B800

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Omron C200H-MD215

Schneider Modicon AS-E485-904 ASE485904 Executive Cartridge

Schneider Modicon Discrete Output Relay AS-BDAP-218

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