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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。目前該型號產品已經被淘汰，而在搬遷后發(fā)現(xiàn)，PLC上電無反應，必須要進行更新?lián)Q代。
　　1　工藝原理
　　本包裝設備，完成對本廠建材產品的包裝，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：對塑料膜進行切斷和封口;③熱縮：使PE膜加熱收縮包裹產品。
　　2　方案選型
　　2.1 控制方案設計
　　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行控制，速度由變頻器進行調節(jié)，為了提高系統(tǒng)操作性能，溫控表和變頻器與PLC進行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，完成數(shù)據(jù)采集、顯示和必要的操作。
　　2.2 PLC選型及IO表設計
　　根據(jù)現(xiàn)場設備匯總需要輸入點13個，輸出點12個，使用 S7-200 SMART系列的SR40型號CPU并設計IO表。
　　2.3 其它主要電氣設備選型
　　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進行通信。
　　2.4 確定通訊方案
　　(1)上位機以太網(wǎng)通信方案本工廠使用的上位機為亞控公司生產的組態(tài)王上位機組態(tài)軟件，經過查找發(fā)現(xiàn)組態(tài)王已經更新了S7-200 SMART的驅動，驅動名稱：S7 TCP.DLL，驅動版本：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構，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　編程與調試
　　3.1 IO控制程序編程與調試
　　塑封膜包裝線中堆垛和封切工序的動作最為復雜，而且各動作也存在著邏輯關系，為了準確執(zhí)行各封切動作，采用步進控制。其他的只采用普通的邏輯控制即可。
　　3.2 MODBUS通信程序編程與調試

Schneider Modicon AS-BZAE-204 High Speed Counter ASBZAE204

Schneider Modicon AS-B805-016 800 I/O MODULE

Schneider Modicon AS-B805-016

Schneider Modicon Motion Module M AS-B885-110 ~REPAIRED SUR~

Schneider Modicon OUTPUT MODULE AS-B828-016

Modicon 992 019 1002 Robot Teach Pendant HHTP

Siemens Analog Input Sub-Module 6ES5 498-1AA51

SEALEDASA5540-AIP20-K9 CISCO 5540 W/AIP-SSM-20 SW HA 4GE1FE 3DES/AES

Siemens MS300 Circuit Board MS3OO 6FX1113-4AD01 6FX11134AD01 6FX1113-4ADO1

SIEMENS SINUMERIK 6FC5203-0AF02-0AA1 no box Free Ship

Spirent SX-7410B Communication Analyzer Module

SIEMENS 6SN1123-1AA00-0CA0 SIMODRIVE 50A WRTYFAST SHIP

SIEMENS 6SN1146-1BB01-0BA2 SIMODRIVE 611 INFEED/REGEN. FEEDBACK MODULE

SIEMENS 6FC5247-0AA02-1AA0 6FC5 247-0AA02-1AA0 SINUMERIK 840D PCI/ISA Adapter

AirTAC Solenoid Valve 4V120-M5 in Box

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

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 88288

ADEPT TECH 10845-72000 USPP 1084572000

(2018) 1 SYMAX INPUT MODULE ANALOG RIM125 SQUARE D (2018)

INDRAMAT DSC3.1-150-115 USPP DSC31150115

TEXAS INSTRUMENTS PLC 555-1101 NSPP 5551101

FANUC A02B-0072-C023 USPP A02B0072C023

CUTLER HAMMER FDPW367T USPP FDPW367T

RELIANCE ELECTRIC 0-57552-4A USPP 0575524A

MODICON PC-E984-685 USPP PCE984685

JOSLYN CLARK 5003-2001-11 NSPP 5003200111

Siemens 6ES5 373-1AA81 -FS- 6ES53731AA81

Siemens 6ES5-605-0UB12 USPP 6ES56050UB12

SIEMENS 6ES5-375-0LC21 USPP 6ES53750LC21

Siemens 6ES5 375-1LA15 -- 6ES53751LA15

Siemens Bus I/O Module 6ES5 700-8MA21

SIEMENS 6SE3212-0DA40 6SE32120DA40 IN BOX

Siemens TP27-6 6AV3 627-1NK00-0AX0 Touchscreen Glass

Siemens 6EW1380-4AB01

MARCONI ATM SINGLE MODE INTERFACE MODULE FOR THE ASX200BX NM4155SMIRD

XYCOM XVME-660 VME BUS XVME 660 XVME660 Inb

Siemens 6ES7 253-1AA22-0XA0 6ES72531AA220XA0 in Box

SIEMENS OPM2 6SE3 290-0XX87-8BF0 OPERATOR INTERFACE

Reliance 0-51839-8

Schneider Modicon AS-B360-001 Relay Output Module ASB360001

Schneider Modicon AS-984B-832 USPP AS984B832

Schneider Modicon AS-P453-612 USPP ASP453612

Schneider Modicon AS-B801-000 ASB801000 B801 Spare Slot

Schneider Modicon AS-B062-P00 / 100-037

MODICON PLC MODULE AS-B824-016 24 VDC OUTPUT

SIEMENS SIMATIC S5 ANALOG INPUT MODULE CAT6ES5464-8MC11

Siemens 6ES7 331-7KF02-0AB0 -- 6ES73317KF020AB0

SIEMENS SIMATIC HMI OP3 6AV3503-1DB10 Operator Panel

SIEMENS 6DD1601-0AE012 mo. warrantyFree UK/EU ShippingPrice Inc UK VAT

SIEMENS Sinumerik Panelfront 6FC5203-0AF02-02-0AA0 Version L_6FC52030AF02020AA0

SIEMENS 90 DAYS WARRANTYDigital High Perbance Control Board

SIEMENS Simodrive 6SN1118-0DJ21-0AA0 6SN11180DJ210AA0

SIEMENS Control Rack 6FC3761-2FA Z_ Genumerik 3G Unit Sinumerik 6FC 3761

AFP8551 Cable USB version for Panasonic FP1/FP3/FP5

Allen-Bradley 2706-E43J32B1 E43J32B1 ser A rev B GOOD

ABB ACH501-050-4-00P2 ACH500 VARIABLE TORQUE AC 50HP 480V-AC MOTOR DRIVE B228004

Acterna TB / MTS-8000 11.1G Optical Ethernet Transport Module T-BERD / MTS 8000

6ES7314-5AE10-0AB0 Brand , Factory Sealed,

87 BARKSDALE 423X-13 PRESSURE TRANSDUCER S 0-3000 PSIG 0-30 VDC NR

SIEMENS 6SE9-221-3DC40 USPP 6SE92213DC40

BANNER ENGINEERING DMSK4848F1 NSFP DMSK4848F1

AUTOMATED LOGIC M0320 NSFP M0320

MODICON AS-9003-821 USPP AS9003821

INDUSTRIAL DEVICES EC5-X-2010B-150-MS6E/MF1-MTE1-42X USPP EC5X2010B150MS6E

BOSTON GEAR F732-60-B7-G USPP F73260B7G

YASKAWA ELECTRIC R84H-M USPP R84HM

Siemens 6ES5-454-7LA11 NSFP 6ES54547LA11

SIEMENS 6ES5 752-0AA12 6ES57520AA12

SIEMENS S5 6ES5 454-7LA11 OUTPUT MODULE

Siemens S5 PLC Cable 6ES5712-8AF00 6ES5 712-8AF00

Siemens 6ES7195-7HD10-0XA0 NIB

Siemens Servo Motor 1FT6 ERN 1387 2048 62S14-70K 0,00

Siemens 3VU9135-1AB04

Hp 583501-001 Hp Bluetooth Module Interface

WELLS FARGO SIEMENS SXR-2 ADDRESSABLE POINT INTERFACE MODULE EXACTPOINT SMT APT

Siemens 6ES5 246-4UA41 ping Worldwide

Siemens LOGO! DM8 12/24R 6ED1055-1MB00-0BA1 NIB

Omron C200H-CN131

Schneider Modicon AS-HDTA-200/ASHDTA200 Primary rack OFFERS

Schneider Modicon 8-point I/O Module ASbdep210 AS-bdep-210

Schneider Modicon AS-I425-100 USPP ASI425100

Schneider Modicon MODICON/ AS-M485-004 MEMORY BOARD XLNT

Schneider Modicon AS-J878-000

Schneider Modicon TSX Compact AS-BDEP-216 Discrete Input

TELEMECANIQUE XBTGT2110 Touchscreen Glass

Schneider Telemecanique TWDPTO220DT TWDPT0220DT FreShip

Siemens TI 505-6408 8 Ch Word Output Module

Siemens 6AV3505-1FB12 6AV35051FB12 COROS OP5

SIEMENS Sinumerik 6FX1120-3BB01 PC Board

Ethernet Communication Module USB SPI ENC28J60 Remote

SIEMENS SIMODRIVE POSMO CD/CA IP 6SN2703-3AA10-0BA1

SIEMENS SIMODRIVE 6SN1145-1BA02-0CA1SINUMETIK 840D NCU-BOX 6FC5247-0AA002ZA

SIEMENS 6 Genuine Printronix 107675-005 OCR Ribbon

Allen-Bradley AB 1746-OG16 /C 1746OG16 TTL Output Module NIB

ABB 086363-002 PC BOARD 086363002

AC TECHNOLOGY M34400B NSFP M34400B

A06B-6058-H025 Drive Fanuc

8 Stec LF-310A-EVD Liquid Mass Flow Controller TEB 0.5g/min

SECO SV3440-01000 USPP SV344001000

ALLEN BRADLEY 6500-PS7DSP USPP 6500PS7DSP

ALLEN BRADLEY 2727-T7P30D1F NSFP 2727T7P30D1F

INDUSTRIAL DEVICES B8962NP USPP B8962NP

GENERAL ELECTRIC DS215SLCCG2AZZ01B USPP DS215SLCCG2AZZ0B

YAMATAKE 82114927-001 USPP 82114927001

MARPOSS 7534250000 USPP 7534250000

Siemens 6ES5-301-5CA12 USPP 6ES53015CA12

SIEMENS 6ES5 421-8MA12 6ES54218MA12

SIEMENS S5 6ES5 312-5CA12 IM312 including cable

Siemens CPU Module 6ES5 944-7UB21 7300

Siemens 6ES7 215-2AD00-0XB0 6ES72152AD000XB0 DP

Siemens OP27 6AV3627-1JK00-0AX0 Operator Display Panel

RELEASE SuperMicro X9DRD-IF Motherboard FULL MFR

Texas Instruments 5TI-1031-1

Telemecanique LA1 LC580BD Interface Module

TSXSCY21601 Modicon Premium 485 MP TSX-SCY-216-01

Siemens DCS Module 6DS1701-8AB IN Box, seal opened,

Modicon MM-PM15-401

Schneider Modicon REMOTE I/O PROCESSOR S908 RIO INTERFACE MODULE AS-J890-101

Schneider Modicon ASBADU204 Compact Analog Input AS-BADU-204

Schneider Modicon AS-BFRQ-254C USPP ASBFRQ254C

Schneider Modicon AS-BZAE-204

Schneider Modicon AS-P120-000 P120 Compact 115/230V AC Power Supply WARRANTY

Schneider Modicon High Speed Counter AS-B883-001

Schneider Telemecanique Overload Relay LRD16KN

SCHNEIDER AUTOMATION MODICON TSX 140DA154000 INPUT MODULE

PWR-950-AC 950W AC P/S FOR CISCO 7600 AND CAT 6500

SIEMENS 6ES5451-4UA12 OUTPUT MODULE 32POINT .5AMP 24VDC IN A BOX

SIEMENS 6DD1640-0AC012 mo. warrantyFree UK/EU ShippingPrice Inc UK VAT

LS INDUSTRIAL G7L-CUEB RS-232C COMMUNICATION MODULE

SIEMENS Simodrive 6SN1123-1AB00-0HA1

SIEMENS Sinumerik 840C/840CE P/Supp 6FC5114-0AA01-1AA0

SIEMENS /MOORE 15994-21-4 PC BOARD MODULE XLNT

Allen-Bradley SLC 500 Cat. 1746-OA16 Output Module Series D

ALLEN BRADLEY RIGHT HAND DOOR HARDWARE KIT 1494V-L3

ABB SACE E2B/E-1600 OUT OF

A06B-0148-B088#0075 FANUC SERVO MOTORS REMANUFACTURED

6x500m/spool Fujikura Panda Type Polarization Maintaining Fiber 1300nm

ORMEC GN3-J594001 USPP GN3J594001

ALLEN BRADLEY 1771-DMC4 NSPP 1771DMC4

ALLEN BRADLEY 1336S-B007-AX-EN-GM1-L4 USPP 1336SB007AXENGM1

GENERAL ELECTRIC DS200IMCPG1CCB USPP DS200IMCPG1CCB

TB WOODS WFC4020-0CHT USPP WFC40200CHT

SQUARE D ATV-58HD23M2XZ USPP ATV58HD23M2XZ

CONTROL TECHNOLOGY INC 2553-1 NSPP 25531

Siemens 6ES5 951-7LD21 6ES59517LD21

Siemens 6ES5 460-7LA11 -

SIEMENS 6ES5-752-0AA12 USPP 6ES57520AA12

Siemens 6ES5 498-1AA11 USPP 6ES5498111AA11

Siemens 6AV6641-0AA11-0AX0 OP73 6AV66410AA110AX0

Siemens LOGO 24RL 6ED1053-1HA00-0BA0

RSP720-3C-10GE Cisco Switch Processor 720 W/10 Gigabit EN upbs Router

Telemecanique TSX SUP 702

SIEMENS Simatic 6ES5441-4UA11 Comm. Interface Module

Wago 750-493/000-001 3-phase power measurement module

Siemens 6SE7090-0XX85-1DA0 ping Worldwide

Modicon AS-P464-001

Schneider Modicon EXPRESS 75 BALLPOINT REFILLS- BLACK FINE-SAME AS 575-FIT K2 PEN

Schneider Modicon AS-B551-001 ASB551001 G266

Schneider Modicon AS-B873-011 USPP ASB873011

Schneider Modicon AS-B825-016 24VDC Input Module True High

Schneider Modicon Fast Input Module AS-B829-116 ASB829116 - Lot of 4

Schneider Modicon AS-J878-000 Modem Module ASJ878000

SCHNEIDER ELECTRIC 140DAO84000 TSX QUANTUM OUTPUT MODULE AC OUT 24-230V

SIEMENS 505-6308 WORD INPUT MODULE 5056308

Reliance Shark 57C554 Remote I/O Interface 57C-554

Siemens 9330 9330DC-126-0ZZZZA Power Meter Display ION Profibus Access

SIEMENS Sinumerik Module Modul #6FC5111-0CA03-0AA2

Prosoft MVI56-GSC Communications Module 2

SIEMENS Module # 6SN1146-1BB00-0EA1 Simodrive 611

SIEMENS SIMODRIVE 6SN1145-1BA01-0DA1SINUMETIK 840D NCU 6FC52476SN11236FC5357

SIEMENS 6FC3984-1FB Tape Reader - Used

Allen-Bradley2707-MVH232MicroViewTerminal

Allen Bradley Terminal Board 9101-1780 Amphenol /Sealed

ABB IRB6600 ROBOT IRB 6600

ZEBRA 090-401-00203-09 USPP 0904010020309

(RR11-1) 1 NIB WESTINGHOUSE A202K3CAZ 100A 600VAC CONTACTOR RR11-1

MITSUBISHI FR-A240-E-37K-TF USPP FRA240E37KTF

ALLEN BRADLEY 1336T-MCB-SP51B NSPP 1336TMCBSP51B

GENERAL ELECTRIC 44B377098-G01 NSPP 44B377098G01

FISHER ROSEMOUNT 3051-CG4A02A1AH2M5 USPP 3051CG4A02A1AH21

SIEMENS 6ES5-902-3SA12 USPP 6ES59023SA12

REXROTH 0-608-820-092 NSPP 0608820092

TEXAS INSTRUMENTS PLC 555-1102 USPP 5551102

Siemens 6ES5 521-8MA21 CP521 SI COMMUNICATION MODULE RE

Siemens 6ES5-981-0HA21 USPP 6ES59810HA21

SIEMENS 6ES5-451-7LA11 OUTPUT MODULE 6ES54517LA11

Siemens 6ES5 316-8MA12 USPP 6ES53168MA12

Siemens S5 Digital Output / 6ES5 441-8MA11

Siemens C98043-A7007-L1-3

Siemens 6ES5 441-4UA11 6ES54414UA11

Square D 8030 CRM-601

Schneider Electric TSXFPCG010 Interface Module FIP/PCMCIA

WMD PDO PHASE DISPLACEMENT OSCILLATOR MODULAR EURORACK MODULE

SIEMENS 6ES7621-6BD02-0AE3 SIMATIC C7-621 ASI ping Worldwide

SIEMENS Touch Glass + Protective film TP177A 6AV6642-0AA11-0AX1

Seco SE2302

Schneider Modicon ASH827103 PERFECT 800 Series Rack AS-H827-103

Schneider Modicon AS-B571-001 NSFP ASB571001

Schneider Modicon CNC Memory Board AS-506P-F12

Schneider Modicon AS-H810-208 USPP ASH810208

Schneider Modicon AS-B840-108 Reed Relay Output

MODICON 5-1/2" PANELMATE PLUS INTERFACE MM-PMC1-100

Siemens 8 Point Input Module Model:505-7028 NIB

Schneider Modicon Premium TSXDEY16A4 TSX DEY 16A4 120VAC Input NIB

Siemens MODULE 8 PT IN 24VDC 5PIN EM141 6ES7-141BF30-0X

SIEMENS Sinumerik 6FX1112-0AA01 E Stand D & 01

SIEMENS SIMATIC S7 CP341 RS232 COMMUNICATIONS MODULE 6ES7 341 6ES7341-1AH01-0AE0

SIEMENS 6SN1123-1AA00-0DA2 ( 6SN11231AA000DA2 ) NIB

SIEMENS 6SN1123-1AB00-0HA1 6SN1 123-1AB00-0HA1 SIMODRIVE 611 Power Module 8A

SIEMENS 6FC5210-0DF05-0AA0 SINUMERIK PCU 50 6FC52100DF050AA0 NIB

AllenBradleyVersaView6176M-15PN/B6176M15PN

ALLEN-BRADLEY 1201-DMA HMI DOOR MOUNT BEZEL

ABB CIRCUIT BOARD DSQC 302

ADEPT TECH 30340-40000 USPP 3034040000

(4) Samsomatic Switches PWA 27-1039 _ PWA271039 _ 143PC03D

INDRAMAT MAC071C-0-JS-4-C/095-A-0/W1520LV USPP MAC071C0JS4C095A

TOPEX 2200-HYC USPP 2200HYC

FANUC A06B-0651-B211 USPP A06B0651B211

DANAHER MOTION MX2000-1C NSFP MX20001C

RELIANCE ELECTRIC 30V4151 USPP 30V4151

MOTOROLA MVME2700-761-I/O USPP MVME2700761IO

LENZE EVS9323-ET NSFP EVS9323ET

Siemens 6ES5 377-0AA32 -- 6ES53770AA32

Siemens 6ES5-701-3LA11 USPP 6ES57013LA11