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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

Schneider Modicon AS-W804-002 ASW804002 Aux Power Cable

MODICON - EATON - IDT - PANELMATE - BOARD P/N 42-13900

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ROBOTRON 503-1-0324-17 USPP 5031032417

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ROOTS I056527-200 NSFP I056527200

ALLEN BRADLEY 6180-FLIEHLDZHZZ NSFP 6180FLIEHLDZHZZ

ALLEN BRADLEY 2711P-K10C4D1 USPP 2711PK10C4D1

INDRAMAT TDM2.1-030-300-W1 USPP TDM21030300W1

YOKOGAWA DX204-2-2/BT11M1 NSFP DX20422BT11M1

XYCOM 98500-001 NSFP 98500001

LENZE E94ASHE0044 USPP E94ASHE0044

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SIEMENS 6ES5 420-4UA14 -FS- 6ES54204UA14

SIEMENS S5 6ES5 300-5CA11 IM 300 Interface Module

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Texas Instruments 560-2820

Tektronix 80A03 TekConnect Probe Interface Module

TV One C2-8160 Corio2 10x2 DVI-U Aud Seamless Switcher

Siemens DCS Module 6DR2803-8C NIB

Modicon MM-FM94-000

Schneider Modicon TSX Compact Subrack DTA 202 - AS-HDTA-202

Schneider Modicon ASB875102 TESTED Analog INPUT Module AS-B875-102

Schneider Modicon AS-BDEP-297 NSFP ASBDEP297

Schneider Modicon AS-BDEP-220 INPUT MODULE ASBDEP220

Schneider Modicon -AS-884A-301

Schneider Modicon DTA 200/AS-HDTA Subrack rack back plane 5

schneider Telemecanique Limit Switch XCE-154 NIB

Schneider Discrete Input Module AS-BDEP-216 DEP 216 WARRANTY

PWR-C49M-1000AC 4900M AC POWER SUPPLY 1000 WATTS

SIEMENS 6ES5451-4UA14 DIGITAL OUTPUT MODULE NIB-FS

SIEMENS 6DD1610-0AG1 SIMADYN D MEMORY MODULE IN BOX

MERCEDES BENZ COMMUNICATION MODULE A 211 820 81 26

SIEMENS Simodrive 6SN1123-1AA01-0FA1 LT-MODUL INT.200A Version A

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SIEMENS /MOORE 16267-1-4 MODULNET INTERFACE CARD 1626714

ALLEN-BRADLEY SLC 500 PLC 1747-ASB ADAPTER WITH INPUT /OUTPUT MODULES

Allen Bradley Safety Relay 700-ZBR100AZ1 700ZBR100AZ1

ABB S4C 3HNE00313-1 Teach Pendant -

A06B-0148-B075 FANUC SERVO MOTORS REMANUFACTURED

0-58706-4

OMRON NT600M-DT211 USPP NT600MDT211

ALLEN BRADLEY 1756-M3 NSFP 1756M3

ALLEN BRADLEY 1336-RFB-80-C USPP 1336RFB80C

GENERAL ELECTRIC DS200LPPAG1AAA USPP DS200LPPAG1AAA

TAYLOR ELECTRONICS 1734FC14200A NSFP 1734FC14200A

SQUARE D 3050-EGW-1 NSFP 3050EGW1

COMPUMOTOR 2100-2-P USPP 21002P

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Siemens SIMATIC S5-110 6ES5 417-7AA21 6ES54177AA21

SIEMENS 6ES5-733-7BD20 NSFP 6ES57337BD20

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SIEMENS 6AV6-545-0AG10-0AX0 MP270B-10" Touch Glass

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RSP720-3CXL-GE Cisco Route Switch Processor 720-3CXL Router

Telemecanique TSX AXM 1 72

SIEMENS Simatic 6ES5301-3AB13 Comm. Interface Module

WAGO 750-653-000-011 Serial Interface RS-485

Siemens 6SE7090-0XX84-0KB0 6SE7 090-0XX84-0KB0 FreeShip

Modicon AS-P371-001

Schneider Modicon Lexium LXM 17D 4A Servo Drive AS MHDA1004A00

Schneider Modicon ASB821008 UNIT Gould 10-60 VDC Input Module AS-B821-008

Schneider Modicon AS-B872-200 USPP ASB872200

Schneider Modicon 24VDC 32 POINT INPUT MODULE MODEL AS-B827-032

Schneider Modicon DISCRETE INPUT AS-BDEP-216 ~ QTY X 6

Schneider Modicon AS-J812-000 Remote I/O adapter J812

Schneider Electric MPCKT55NAX20N Magelis Compact PC 15 Inch Touchscreen

Siemens 6ES5 421-8MA12 Digital Input Module NIB

Rev 1.1 SuperMicro H8DAE-2 Bulk Pack MB Support Dual Core CPU

SIEMENS 9510DC-1156-AEZA/9510DC1156AEZA ION ACCESS DISPLAY NIB

SIEMENS Sinumerik Module 6FX1120-5BA01 E Stand E & 00

ProSoft Technology 3150-MCM Modbus Communication Module SLC-500 1747-KE

SIEMENS FILTERMODULE POSMO 6SN2414-2TX00-0AA1

SIEMENS SINUMERIK 802D 6FC5603-0AD00-0AA1 6FC56030AD000AA

SIEMENS 6FC3984-3RA 6FX1124-6AD02 I/O Module - Used

AllenBradley2711-B6C10/C2711B6C10

Allen Bradley Terminal Keyboard 1770FD PLC Overlay 1770-KBA PN 610716-01

ABB IRB 7600 SER 76-27020 ROBOT S4C PLUS CNTRLR TEACH PENDANT W/ MATCHED SET

Advanced Research - System 31-05 - 30A Ground Bond w/ 5kVAC HiPot Testing Units

(Q7-1) 1 ALLEN BRADLEY 1336F-B030-AN-EN-HAS2-LA2-L6-MX3 FREQUENCY CONTROL Q7-1

MICROSWITCH 82114805-501 USPP 82114805501

ALLEN BRADLEY 1336S-B030-AA-EN-HA1-L6 USPP 1336SB030AAENHA1

GENERAL ELECTRIC 193X-530BBG01 NSFP 193X530BBG01

FANUC A20B-0010-0100 USPP A20B00100100

SIEMENS 6ES5-512-5BC21 NSFP 6ES55125BC21

RELIANCE ELECTRIC 9101-0378 USPP 91010378

STI MS4460B-2-X USPP MS4460B2X

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Siemens 6ES5-955-3LC14 USPP 6ES59553LC14

SIEMENS 6ES5-451-4UA11 6ES54514UA11 DO

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Siemens S5 Digital Input / 6ES5 421-8MA12 8xDC

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Square D 8030 CRM-232

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WOODWARD NETCON 5000 5466-031 REV D I/O CONTROLLER

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Schleicher USP 2A U 31507501 622 114

Schneider Modicon ASHDTA201Compact Subrack AS-HDTA-201

Schneider Modicon AS-B558-001 USPP ASB558001

Schneider Modicon AS-W922-008 NSFP ASW922008

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MODICON 91-00992-02 1PH 85VA 110/230VOLTS 50/60HZ MONITOR REFURBISHED

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SINGLE POINT

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ALLIS CHALMERS CB26400 NSPP CB26400

ALLEN-BRADLEY 1400E 2711E-K14C6 SER A REV B PANELVIEW TERMINAL

ABB BI Vector 500 Drive

ADEPT TECH 30330-12000 USPP 3033012000

(3)GOULD BREAKER TYPE K-1600S / FRAME SIZE 1600A /SOLID STATE TRIP ITE TYPE SS

INDRAMAT KDS-1.1-100-300-W1-220 USPP KDS11100300W1220

TEXAS INSTRUMENTS PLC 565-2820 NSFP 5652820

FANUC A06B-0356-B755 NSFP A06B0356B755

CUTLER HAMMER JDC3250VWH09 USPP JDC3250VWH09

RELIANCE ELECTRIC 11C83K NSFP 11C83K

MOORE PRODUCTS 16114-171/04 USPP 1611417104

KAWASAKI TRC-5052 USPP TRC5052

Siemens 6ES5 374-2FJ21 6ES5374-2FJ21 XLT

Siemens 6ES5-696-3AA21 NSFP 6ES56963AA21

SIEMENS 6ES5-375-0LC41 USPP 6ES53750LC41

Siemens 6ES5 375-1LA21 Memory Sub Module 17030

Siemens CPU 948- 6ES5 948-UA22 very rare

Siemens 6SE6420-2UC11-2AA1 6SE6 420-2UC11-2AA1 NIB FS

Siemens TP27-6 6AV3627-1NK00-2AX0 Touchscreen Glass

Siemens 6FM1470-7AA25

Measurement Technology LTD MTL 8512-IF-HA HART Interface Module

XYCOM 70240-001 REV 1.1 I/O MODULE VME BOARD

Siemens 6ES7 291-8GF23-0XA0 64K Memory Card NIB

Siemens PC/MPI+ PC MPI+ PLC Programming Serial Cable

Reliance 0-51847-2

Schneider Modicon AS-B351-001 ASB35101 AC Input NIB FS

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Able Reducer VRKF-15C-200 Gear Ratio 1:15

ALLEN-BRADLEY 2706-D21J2 OPERATOR INTERFACE DATALINER

ABB ACH550-UH-059A-4 ADJUSTABLE FREQUENCY AC 40HP 480V-AC MOTOR DRIVE B227968

ACTERNA TTC T-BERD 2209 HANDHELD T1 DS3 TEST SET A+++

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882I60930 Marposs GUAGE T5

SIEMENS 6SE9-531-4DK40 NSFP 6SE95314DK40

BARDAC PLX145/330 USPP PLX145330

AVG UTICOR 100G-UT15T3R1 USPP 100GUT15T3R1

MODICON AS-C184-004 USPP ASC184004

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Siemens 6ES7214-2AD23-0XB0

Siemens Simatic 6ES5 095-8MB01 6ES5095-8MB01

Siemens 505-6208A

Hp 81531A Optical head interface module

Wieland Bamberg WEB-1001 EGM Encoder Interface Module

SIEMENS 6ES5 375-0LC21 6ES53750LC21

Siemens LOGO! PC CABLE 6ED1 057-1AA00-0BA0 PC-LOGO

Omron C200H-ID212

Schneider Modicon AS-H827-103 Gould 11 Slot 800 Series Rack

Schneider Modicon Analog Output Module AS-BDAU-202

Schneider Modicon AS-J200-001 USPP ASJ200001

Schneider Modicon MODICON/ AS-W808-002 CABLE ASSEMBLY REMOTE I/O SIG XLNT

Schneider Modicon AS-M480-004

Schneider Modicon TSX Compact M AS-BDAP-218 ~ SURPLUS~

SMCSI EX250-IE3 DEVICENET INPUT MODULE

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SIEMENS Simodrive Posmo A 1FK6032-2AF1 s/n 22253202 6SN2155-2BD10-1BAO

SIEMENS SIMODRIVE 6SN1145-1BA02-0BA1SINUMETIK 840D NCU-BOX 6FC52476FC53562ZM

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Allen-Bradley 855PDB24MEH4322 Operator Indicator Light 24VAC/DC Red/Green

ABB 15 KV Advac Panel Cell Vacuum Breaker Medium Voltage SafeGear w/ PT complete

ACBE17FPU 17" FLAT PANEL MONITOR UPGRADE KIT

A06B-6058-H322 FANUC SERVO AMPLIFIER - -

8" LCD 800x600 Video Zoom Microscope 3.3x-147x w/ Track Stand

SEW EURODRIVE MDX60A0220-503-4-00 USPP MDX60A0220503400

ALLEN BRADLEY 803-A12 NSFP 803A12

ALLEN BRADLEY 3500-P10 USPP 3500P10

INTERMEC J2050-A-07102 USPP J2050A07102

GENERAL ELECTRIC DS3800HPMA1E1D USPP DS3800HPMA1E1D

YAMATAKE 82408470-001 USPP 82408470001

MERLIN GERIN NFNF-36225-AAHJ00 NSFP NFNF36225AAHJ00

Siemens 6ES5-305-7LB11 MODULE 6ES53057LB11

SIEMENS 6ES5 430-4UA12 6ES54304UA12

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Siemens Digital Input 8 x 24VDC 6ES5 431-8MA11