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　　1 引言

　　紡絲機(jī)紡出的滌綸原絲需經(jīng)過(guò)牽伸定型后,才具有一定的纖度、強(qiáng)度、伸度和其它的物理性能。VC443A牽伸加捻機(jī)用于滌綸復(fù)絲生產(chǎn)過(guò)程中牽伸加捻工序。牽伸絲為低捻復(fù)絲，可直接或經(jīng)加彈工序后供綢廠使用。它的電氣部分由電源控制系統(tǒng)、程序控制系統(tǒng)、錠子交流變頻調(diào)速系統(tǒng)、熱盤(pán)控制系統(tǒng)、熱板控制系統(tǒng)組成。隨著機(jī)電一體化技術(shù)的發(fā)展，對(duì)系統(tǒng)的可靠性要求愈來(lái)愈高，因PLC具有控制可靠、體積小、功能強(qiáng)、速度快,組態(tài)靈活和可擴(kuò)展性的特點(diǎn)而得到了廣泛的應(yīng)用，成為自動(dòng)化系統(tǒng)中的基本電控裝置，故VC443A牽伸加捻機(jī)選用PLC可編程控制器，實(shí)現(xiàn)了生產(chǎn)的自動(dòng)控制。

　　2 PLC選型設(shè)計(jì)

　　系統(tǒng)選用了日立公司的產(chǎn)品:E-64HR可編程控制器,作為主控單元，它有64個(gè)輸入/輸出點(diǎn),其中40個(gè)開(kāi)關(guān)量輸入點(diǎn)，24個(gè)輸出點(diǎn)，內(nèi)置式電擦除EEPROM可以保護(hù)用戶(hù)方便的完成程序和參數(shù)的修改和存儲(chǔ), PLC根據(jù)各輸入點(diǎn)所接按鈕，接近開(kāi)關(guān)，接觸器等電器信號(hào)的狀態(tài)以及編制的軟件程序自動(dòng)控制各電機(jī)，電磁閥，指示燈等，完成整個(gè)生產(chǎn)的工藝動(dòng)作程序，鋼領(lǐng)板換向及成型自動(dòng)控制。E-64HR具有多種編程工具:通用編程器PGMJ-R和標(biāo)準(zhǔn)編程器PGNJ等，體積小攜帶方便，可在現(xiàn)場(chǎng)實(shí)地進(jìn)行程序調(diào)整和傳送。全部控制程序約276條，可見(jiàn)該系統(tǒng)軟硬件資源得到了相當(dāng)充分的利用。

　　3 VC443A牽伸加捻機(jī)工藝

　　3.1 輸入信號(hào)

　　VC443A牽伸加捻機(jī)控制系統(tǒng)的輸入信號(hào):主令按鈕、限位開(kāi)關(guān)、接近開(kāi)關(guān)、鈕子開(kāi)關(guān)、撥盤(pán)開(kāi)關(guān)的投入信號(hào)，全部為直流輸入，共有40點(diǎn)。

　　3.2 輸出信號(hào)

　　控制的負(fù)載主要分成三類(lèi):一是7臺(tái)交流電機(jī):牽伸雙速電機(jī)M1、油泵電機(jī)M2、靠模升電機(jī)M3、靠模降電機(jī)M4、移絲電機(jī)M5、錠子電機(jī)M6、風(fēng)機(jī)M7;二是用于控制鋼領(lǐng)板升降及側(cè)壓輥壓差的電磁閥;三是信號(hào)燈;四是計(jì)數(shù)器，共有24點(diǎn)，全部為繼電器接點(diǎn)輸出信號(hào)。

　　3.3 開(kāi)車(chē)主要控制過(guò)程

　　(1) 按“油泵開(kāi)”按鈕SB7，使接觸器KM5吸合， 油泵開(kāi)指示燈亮, 油泵電機(jī)M2運(yùn)轉(zhuǎn)。(程序器的輸出50對(duì)應(yīng)的LED發(fā)光)。

　　(2) 按“低速開(kāi)”按鈕SB9。

　　●輔助接觸器KA1吸合，錠子低速運(yùn)轉(zhuǎn)。(程序器的輸出51對(duì)應(yīng)的LED發(fā)光)

　　●程序器控制下，使計(jì)數(shù)器復(fù)零，進(jìn)入準(zhǔn)備工作狀態(tài)，內(nèi)部定時(shí)器T01 T02接通，使鋼領(lǐng)板強(qiáng)迫進(jìn)入廢絲盤(pán)位置，待TO0延時(shí)到斷開(kāi)快速閥YV3，鋼領(lǐng)板在程序器控制下微動(dòng)。(程序器的輸出76、65對(duì)應(yīng)的LED發(fā)光，延時(shí)到熄滅，66、67對(duì)應(yīng)LED交替發(fā)光)

　　●定時(shí)器TO1延時(shí)到，使接觸器KM3吸合，牽伸雙速電機(jī)M1帶動(dòng)牽伸羅拉和上下?tīng)拷z盤(pán)低速運(yùn)轉(zhuǎn)，低速指示燈亮，進(jìn)入掛絲階段。(程序器的輸出52對(duì)應(yīng)的LED發(fā)光)

　　(3) 按“高速開(kāi)”按鈕SB11。

　　●輔助接觸器KA2吸合，使錠子高速運(yùn)轉(zhuǎn)。(程序器的輸出53對(duì)應(yīng)的LED發(fā)光)

　　●程序器控制使電磁閥YV4斷電，側(cè)壓輥加壓。(程序器輸出64對(duì)應(yīng)LED發(fā)光)

　　●定時(shí)器T02接通，延時(shí)到后接觸器KM4得電，牽伸雙速電機(jī)M1切換為高速運(yùn)轉(zhuǎn)，高速指示燈亮，繼電器KA3吸合，移絲電機(jī)M5運(yùn)轉(zhuǎn)。(程序器輸出54對(duì)應(yīng)的LED發(fā)光。55對(duì)應(yīng)的LED發(fā)光)

　　●定時(shí)器T03延時(shí)到后，鋼領(lǐng)板強(qiáng)迫上升，靠模上撞塊使底部打結(jié)開(kāi)關(guān)SA2接通，定時(shí)器T04得電，使上升閥失電，實(shí)現(xiàn)底部打結(jié)，T04延時(shí)到上升閥YV1/1再次得電，強(qiáng)迫鋼領(lǐng)板快速上升，進(jìn)入正常牽捻區(qū)，待T05延時(shí)到后切斷快速閥YV3，鋼領(lǐng)板在程序器控制下，以正常速度運(yùn)動(dòng)，同時(shí)接通繼電器KA4，靠模升電機(jī)M3運(yùn)轉(zhuǎn)，帶動(dòng)靠模緩慢上升，計(jì)數(shù)器開(kāi)計(jì)長(zhǎng)(程序器56對(duì)應(yīng)的LED發(fā)光。65對(duì)應(yīng)的LED在接通快速閥時(shí)發(fā)光，74對(duì)應(yīng)的LED發(fā)光，有計(jì)長(zhǎng)信號(hào)時(shí)發(fā)光指示)。

　　至此開(kāi)車(chē)過(guò)程結(jié)束，機(jī)器進(jìn)入正常紡絲。
 

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數(shù)字量輸入/輸出模塊SM 6ES7 322-1BH01-0AA0 DO/16 24VDC，0.5A，可控硅輸出，光電隔離，20pin前連接器

行程開(kāi)關(guān) 3SE53122SJ12

運(yùn)行版軟件 6AV2105-2KK04-0AC0 SIMATIC WinCC Runtime 專(zhuān)業(yè)版 Powerpack Runtime Advanced 8192 PowerTags -> Runtime 專(zhuān)業(yè)版 8192 PowerTags V14

1585J-M8CBJM-11 RJ45 Ethernet Media

1756-PB75K ControlLogix DC Power Supply

188-K1D010-N Miniature Circuit Breaker 1 A

194E-Y16-1753-4A 16 A 194E Load switch

2090-CFBM7DF-CEAF75 75 m Length SpeedTec Flexible Cable

2090-UXNFBMP-S15 MP-Series 15 m Length Feedback Cable

BC646TPD000 ProServer Unlimited Develop/Runtime Systems with Proficy GlobalCare

GC647IFESGSR00075 GCC iFIX Optn: ESig & ERec 75 I/O Srv

IC200BEM002CA PLC PROFIBUS-DP NETWORK SLAVE Conf Coat

IC646MGRS03 Electronic Signature Option for a 3 User Proficy Change Management system

IC647IFPRRNUNLMTK iFIX Profsnl SCADA Unlimited Runtime (M1 Kit Part)

IC660TBD023 Terminal Assembly for IC660BBD023

IC697CMM712 Serial Communications Module for State Logic

IC800MCUB12160XN 50 oz-in stepping Motorcube with pulse/direction interface

ControlLogix/1756 System 1756-IB32 10-31 VDC INPUT 32 PTS (36 PIN)

Industrial Computers 6182H-7TRH4D VVCE 700, TOUCH, STD MEM, ENET, DC

Process Control 9358-PBNT30ENE RSBATCH NT FOR PROCESSLOGIX 30 UNITS

Operator Interface 2711P-RAK4 CUTOUT ADAPTER TO MOUNT PV PLUS 400 KEYPAD

Support 9352-WPM100S SUPT RENEWAL CONTRACT FOR 9352WPM100

Support 9351-AIXRTR SUPT REINSTATEMENT CONTRACT FOR 9351AIXRT

ControlNet Products 1786-TPR CONTROLNET T-TAP/RIGHT ANGLE

RSI Software Products 9301-2SE235KOU2R RSVIEW32 WORKS 300-5K UPGRADE OUT-SUPT (KO)

RSI Software Products 9355-WABESE RSLINX PRO - SPANISH

Motion Control MPL-A310P-HJ22AA MOTOR,SERVO,1.58NM,5000RPM,ENCDR,230V,3.0KG

Motion Control 2090-DANFCT-S05 CABLE, NF, MTR FBACK FOR CABLE-MTD CONN, T, 05M

BC647MOP001 Logic Developer PC with View - Development ONLY Supports up to 8000 I/O tags and with Proficy GlobalCare Complete and a hardware key

IC5002TAW2000 Discontinued - Order a BC5002TAW0000 & Appropriate CIM PE Software

IC800CBL066 Use IC800CBL069 for New Applications: AC12/2000 Motor Power Cable, 14 Meters

OC647HSTSCADA2500 Proficy Historian for SCADA 2500 pts

20AD014A3AYYAEC0 PowerFlex 70 AC Drive 14 A at 10 Hp 20A

20DC125A0EYNANANE PowerFlex 700S AC Drive 20D

20G1AND415AN0NNNNN PowerFlex 755 AC Packaged Drive

25C-D024N114 PowerFlex 527 11kW (15Hp) AC Drive

280-MTRF22-M8 ArmorConnect Brake and Motor Cable

FX1S-10MR-001 主機(jī)6點(diǎn)入/ 4點(diǎn).出 繼電器輸出

1492-M5X12 IEC 5 x 12 mm Marker Card

1494H-BN3N Heavy Duty Non-Fus Safety Discon Switch

軟啟動(dòng)器 3RW44446BC36

ET 200SP 6ES7136-6BA00-0CA0 故障安全型模塊F-DI 8x24VDC 高性能型，基座單元類(lèi)型A0

1585D-M4TBDM-15 Micro D-Code, QD Style Ethernet Media

1756-CP3 Logix Family RS232 Programmer Cable

1794-OA8 Flex 8 Point Digital Output Module

194E-CA32E-PE-TN 194E Load switch

2085-ECR Micro800 Expansion Module End Cap

2090-DANBT-18S03 TL-Series 3m Brake Cable

20AC5P0C0AYNANC0 PowerFlex 70 AC Drive 5 A at 2.2 kW 20A

GC646MSS101 Proficy GlobalCare Complete for Logic Developer - State Standard w/Programming Cable

HE693THM409 4 ch. J, K, N, T, E, R, S, 0.5 deg C resolution, deg C/deg F engr. units

IC630MDL301RR 24Vdc Sink Input Module (16 points)

IC647HSTSS30KM-35 Historian v3.5 Standard Server 30000 Points (M4 Key)

IC660BLA021 Cover w/Label for IC660BBA021

IC695ALG616 Analog Input module, 16 channels single ended, 8 channels differential, channels are configurable for voltage and current. Can be configured for Current: 0 to 20mA, 4 to 20mA, +/- 20mA; Voltage: +/- 10V, 0 to 10V, +/- 5V, 0 to 5V, 1 to 5V. The ana

IC756WDV009E-23 DV Development Sys Visual Basic, English, Version 2.3

CompactLogix System 1769-IR6 6 CHANNEL RTD/RESISTANCE INPUT MODULE

PLC-5/1771 System 9399-FW5FBGR RSLGIX FRAMWRKS FUNCTION BUILD.GET'G RESULTS GUIDE

Distributed I/O 1799-MP20 PLASTIC MOUNTING PLATE/4 SCREWS-20 PT BOARD

Operator Interface 2711P-T6C3D PV PLUS 600 COLOR, TOUCH, DH485, DC PS

Support 9342-L2200R SUPT REINSTATEMENT CONTRACT FOR 9342L2200

Support 9358-PBPC03S SUPT RENEWAL CONTRACT FOR 9358PBPC03ENE

Support F1779-KFMSERA FIRMWARE UPGRADE FOR 1779-KFM COMMUNICATION MODULE