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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(jì)
　　針對本系統(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

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