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在企業(yè)搬遷工作中，原來在包裝崗位有兩臺(tái)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(hào)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(duì)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(duì)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(jì)
　　針對(duì)本系統(tǒng)的特點(diǎn)，適合采用集成了IO點(diǎn)的小型PLC。而溫度可以單獨(dú)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(shí)，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(jì)
　　根據(jù)現(xiàn)場(chǎng)設(shè)備匯總需要輸入點(diǎn)13個(gè)，輸出點(diǎn)12個(gè)，使用 S7-200 SMART系列的SR40型號(hào)CPU并設(shè)計(jì)IO表。
　　2.3 其它主要電氣設(shè)備選型
　　另外選擇了1臺(tái)安川V1000變頻器和2臺(tái)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(dòng)，驅(qū)動(dòng)名稱：S7 TCP.DLL，驅(qū)動(dòng)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(dòng)作最為復(fù)雜，而且各動(dòng)作也存在著邏輯關(guān)系，為了準(zhǔn)確執(zhí)行各封切動(dòng)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

Schneider Modicon AS-B825-016 INPUT MODULE 800 I/O 24VDC TRU HI IN 16PT

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Advantech Remote Contact/Digital Input ADAM-4053

Allen-Bradley 2711-B6C1 Panelview 600 NIB

ABB 64513591 MAIN CIRC. INTERFACE NINT-72C SEALED

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853-012500-003 DETECTOR, EDGE ASSY TYPE

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BAILEY CONTROLS IMMFP-03 NSPP IMMFP03

ASEA BROWN BOVERI YT204001-FSI1 USPP YT204001FSI1

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ASEA BROWN BOVERI YB560103-CH USPP YB560103CH

VIDEO JET 358160-E NSFP 358160E

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SIEMENS 6ES5 700-2LA12 6ES57002LA12

SIEMENS S5 6ES5 377-0AB31 6ES53770AB31 NIOB

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HONEYWELL TC-CCR012 REDUNDANT NET INTERFACE MODULE

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Siemens LOGO! 6ED1 052-1HB00-0BA6 NIB + LOGO USB Cable

Omron 3G2A9-AL001

Schneider Modicon AS-J878-000 MODEM MODULE ASJ878000

Schneider Modicon PROGRAMMABLE CONTROLLER AS-584L-231 W MEM

Schneider Modicon AS-H827-100 ASH827100 Fast Shipping

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Schneider Modicon AS-C921-100

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SIEMENS Sinumerik 6FC5412-0FA10-0AA0 Impuls Adapt .

FX-232ADP Mitsubishi PLC RS-232 Communication Module FX232ADP

SIEMENS Simodrive UEB - Module Int/Ext. 6SN1112-1AC01-0aa1 SURPLUS

SIEMENS SIMODRIVE 6SN1146-1AB00-0BA1SINUMETIK 840D NCU-BOX 6FC52476FC5356 2NC

SIEMENS 04-07VWTOUAREGKEYLESSREMOTE3D0959753 OFCC:KR55WK45022GERMANYHUF

Allen-Bradley A-B PanelView 1400e Terminal 2711E-K14C6X

AB,ALLEN-BRADLEY BULLETIN GMC DIGITAL SERVO CONTROR 10KW 1394 ,AXIS 10KW,IM

AC Servo Controller AC Main Spindle Drive KDV; KDS; KDA

A06B-0819-B001 FANUC AC SERVO SPINDLE REMANUFACTURED

75HP VERTICAL MOTORS, 3600 RPM VSS, TEFC , 230-460V, 365LP

REXROTH 1070070309 NSFP 1070070309

ALLEN BRADLEY 6170-DCCE1A1EBZZ USPP 6170DCCE1A1EBZZ

ALLEN BRADLEY 2711-B6C20 NSPP 2711B6C20

INDRAMAT MDD112B-N-040-N2L-130PA0 NSPP MDD112BN040N2L13

YASKAWA ELECTRIC SGDH-75AE NSPP SGDH75AE

WHEDCO IMC-3161-2-B NSPP IMC31612B

KAWASAKI 50817-1116R01 USPP 508171116R01

Siemens 6ES5-254-4UB21 USPP 6ES52544UB21

SIEMENS 6ES5 385-8MB11 6ES53858MB11

SIEMENS PLC INPUT MODULE 6ES5 430-7LA12 VER 3

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RELEASE SuperMicro X9SAE MB ※Check W/ Us for Availability FIRST※

Texas Instruments 510-2101

SYMAX Square D 8030 CRM222 8030CRM222 Remote Interface Module Series G

Tyan S8236GM3NR-IL Socket G34 AMD SR5690/SP5100 Chipset EEB Motherboard

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Modicon MA-0212-001

Schneider Modicon /GOULD/AS-884A-101 PROCESSOR 2K W/REMOTE I/O

Schneider Modicon ASB838032 24 VDC Output Module AS-B838-032

Schneider Modicon AS-BDEP-218 NSFP ASBDEP218

Schneider Modicon AS-BDEP-210 ASBDEP210 G302

Schneider Modicon -AS-5512-000

Schneider Modicon DISCRETE COMBO AS-BDAP-220 QTY X 3

Schneider Telemecanique BMXP342020

SCHNEIDER INPUT MODULE 170ADI35000

Q64TDV-GH Mitsubishi PLC Milivolt Analog Input 4 Pt Isolated Q64TDVGH

SIEMENS 6ES5452 - 8MR11 RELAY OUTPUT MODULE

SIEMENS 6DD1606-0AD1 NSFP 6DD16060AD1

MERCEDES S W220 Communication Telephone Module TELEAID A2108208026

SIEMENS SIMODRIVE 6SN1123-1AA00-0HA0

SIEMENS SINUMERIK 840D/DE NCU 573.4 6FC5357-0BB34-0AA0 6FC53570BB340AA0 NIB

SIEMENS /MOORE 39ACM24BDN/16139-205 ADVANCED CONTROL MODULE XLNT

Allen-Bradley SLC500 Output Module 1746-OX8 Series A

ALLEN BRADLEY SLC 500 16-CHAN OUTPUT MODULE 1746-OW16

ABB ROBOTICS SERVO MOTOR,PS130/6-200-P-PMB-4136

A06B-0147-B084#7076 FANUC SERVO MOTORS REMANUFACTURED

0-51901

OMRON 3G3RV-B2370-AV1 NSFP 3G3RVB2370AV1

ALLEN BRADLEY 1756-L62S USPP 1756L62S

ALLEN BRADLEY 1336F-BRF150-AA-EN-GMS6 USPP 1336FBRF150AAEN1

GENERAL ELECTRIC CR306G002 NSFP CR306G002

SYMAX 8020-SCP-544 NSFP 8020SCP544

SIEMENS OP-20/220-5 USPP OP202205

CARRIER HK50AA001 USPP HK50AA001

Siemens 6ES5 948-3UA11 6ES59483UA11

Siemens Simatic S5 6ES5-470-7LB11 Analog Output Module

SIEMENS 6ES5-725-0AK00 NSFP 6ES57250AK00

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SIEMENS LOGO 230RC 6ED1 052-1FB00-0BA1 6ED1052-1FB00-0BA1 #1

S HP 4Gb Virtual Connect Fibre Channel 409513-B21

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SIEMENS 6SE7090-0XX84-0AD1 Card 6SE70900XX840AD1 version 99% , no box

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Schneider Modicon AS-B872-100 ASB872100

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AllenBradley2711E-T10C6PanelView1000ETouchscreenInterfaceRev.D

Allen Bradley Transber Pilot Light 800T-P26

ABB IRB 2400 SER 24-29214 ROBOT S4C PLUS CNTRLR TEACH PENDANT W/ MATCHED SET

Advanced Fiber Solutions OLK61-SM-SC, SM source and Meter 1310/1550 SC

(Q3-1) 1 GE SKPA36AT1200 CIRCUIT BREAKER Q3-1

MEASUREX 51401288-200 USPP 51401288200

ALLEN BRADLEY 1336F-BX040-AX-EN-L6 USPP 1336FBX040AXENL6

GEMCO ELECTRIC 1989-A-16-R-12-S-C-M NSPP 1989A16R12SCM

FANUC A16B-3200-0330 USPP A16B32000330

SIEMENS 6ES5-241-3CA13 USPP 6ES52413CA13

RELIANCE ELECTRIC 610113T NSFP 610113T

SIEMENS HMD63F800 USPP HMD63F800

Siemens 6ES5 470-8MA11 6ES54708MA11

Siemens 6ES5-951-7LD21 NSPP 6ES59517LD21

SIEMENS 6ES5-441-8MA11 6ES54418MA11 INPUT MODULE 5 NOS WITH BASE

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Schneider Modicon ASM780032 BRANDMemory Module AS-M780-032

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Schneider Modicon AS-B828-016/ASB828016 Output Module

MODICON AEG DAP 210/AS-BDAP-210 OUTPUT MODULE

SIEMENS DIGITAL INPUT MODULE 6ES5 430-7LA12

SERIES7 SLATE I5-2467M 1.6G 4GB PN XE700T1A-A05US

Siemens OP15 Operator Panels 6AV3515-1EB00 NIB

SIEMENS Sinumerik 6FC5203-0AD27-0AA0 Operator Panel

Standard Communications AVM-860 Modulator/UP Converter

SIEMENS 6SN1123-1AA00-0BA1 6SN11231AA000BA1 Simodrive

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Advantest Teach Pendant Teaching Programmer 0401004AA

ALLEN-BRADLEY 160-BA01NPS1P1 0.5HP 460VAC Control. in good condition

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 88271

ADEPT TECH 10337-15200 NSPP 1033715200

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INDRAMAT DSC1.4-50 USPP DSC1450

TELEMECANIQUE VW3RZD1122 NSFP VW3RZD1122

EUROTHERM DRIVES 620STD/0750/400/0020/UK/ENW/0000/000/B0/000/000 USPP 620STD0750

CUTLER HAMMER ECN2419CAC NSFP ECN2419CAC

RELIANCE ELECTRIC 0-56303 NSFP 056303

MODICON NW-BM85C-002 USPP NWBM85C002

JOHNSON CONTROLS AS-AHU-101-0 USPP ASAHU1010

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Siemens 6ES5-581-0EA11 NSPP 6ES55810EA11

SIEMENS 6ES5-375-0LA41 USPP 6ES53750LA41

Siemens 6ES5 375-0LA15 6ES53750LA15 Memory Submodule 8K X 8 Bit -

Siemens AI 5V 6ES5465-4UA13

Siemens 6RA70 PMU Panel C98043-A7005-L1

Siemens TP270-6 6AV6545-0CA10-0AX0 Touch Glass

Siemens 6ES7315-2AF02-0AB0

LUTRON GRAFIK EYE FLOUR DIMMING BAL INTERFACE GRX-FDB1-16A-120 FREE

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Schneider Modicon AS-9594-001 NSFP AS9594001

Schneider Modicon AS-P451-581 USPP ASP451581

Schneider Modicon AS-B560-001 USPP ASB560001

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MODICON SQUARE D TXB TF024510E INTERFACE TXBTF024510E

SIEMENS SIMATIC S5 DIGITAL INPUT MODULE CAT6ES5431-8MA11

Siemens 6ES7 331-7RD00-0AB0 -FS- 6ES73317RD000AB0

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SIEMENS 3SF7834-6DD00 NSFP 3SF78346DD00

SIEMENS SINUMERIK OP 032S 6FC5203-0AB20-1AA0

SIEMENS 6SN1123-1AA00-0DA0 SIMO DRIVE

SIEMENS Simodrive 6SN1118-0NH00-0AA1 Servo Control Module

SIEMENS CONTROLLER CARD 6FC5356-0BB11-0AE1

Advantech TPC-650 display panel

ALLEN-BRADLEY 2711-B5A2 Panelview 550 Series F WOW

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ACTERNA JDSU TTC-2000 2510-15SC T-BERD 10GB TEST PAD NETWORK TESTER TTC2000

6ES7151-2AA00-0AB0 Brand , Factory Sealed,

86142A Agilent HP, Optical Spectrum Analyzer, Calibrated, 90 Days

SIEMENS 6SE9-215-8DB40 NSFP 6SE92158DB40

BALDOR KBM3456 NSFP KBM3456

ATLAS COPCO ETVS4-10-10-CTADS USPP ETVS41010CTADS

MODICON AS-884A-111 USPP AS884A111

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BAYSIDE PG115100 NSPP PG115100

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SIEMENS 6ES5 731-1CF00 6ES57311CF00

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Siemens S5 Operator Interface OP393 6ES5 393-OUA11