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　PLC控制系統(tǒng)的設(shè)備與調(diào)試，觸及到各項(xiàng)作業(yè)，而且只能按序進(jìn)行，一環(huán)緊扣一環(huán)，稍有不小心都將導(dǎo)致調(diào)試失利，不但延誤工期，甚至?xí)p壞設(shè)備。本文介紹了在現(xiàn)場(chǎng)實(shí)踐中總結(jié)出的PLC控制系統(tǒng)的設(shè)備與調(diào)試技能經(jīng)驗(yàn)，并對(duì)現(xiàn)場(chǎng)經(jīng)常出現(xiàn)的設(shè)備、調(diào)試相關(guān)問(wèn)題，提出評(píng)論定見(jiàn)和解決計(jì)劃。

　　一、體系的設(shè)備與調(diào)試

　　合理安排體系設(shè)備與調(diào)試程序，是確保高效優(yōu)質(zhì)地完成設(shè)備與調(diào)試任務(wù)的要害。

　　1、前期技能準(zhǔn)備

　　體系設(shè)備調(diào)試前的技能準(zhǔn)備作業(yè)越充沛，設(shè)備與調(diào)試就會(huì)越順暢。前期技能準(zhǔn)備作業(yè)包含下列內(nèi)容：

　　(1)熟悉PC隨機(jī)技能材料、原文材料，深化了解其功用、功用及各種操作要求，制定操作規(guī)程。

　　(2)深化了解規(guī)劃材料、對(duì)體系工藝流程，特別是工藝對(duì)各生產(chǎn)設(shè)備的操控要求要有全面的了解，在此基礎(chǔ)上，按子體系制造工藝流。程聯(lián)鎖圖、體系功用圖、體系工作邏輯框圖、這將有助于對(duì)體系工作邏輯的深刻了解，是前期技能準(zhǔn)備的重要環(huán)節(jié)。

　　(3)熟悉各工藝設(shè)備的功用、規(guī)劃與設(shè)備狀況，特別是各設(shè)備的操控與動(dòng)力接線圖，并與什物相對(duì)照，以及時(shí)發(fā)現(xiàn)過(guò)錯(cuò)并糾正。

　　(4)在全面了解規(guī)劃計(jì)劃與PC技能材料的基礎(chǔ)上，列出PC輸入輸出點(diǎn)號(hào)表(包含內(nèi)部線圈一覽表，I/O所在位置，對(duì)應(yīng)設(shè)備及各I/O點(diǎn)功用)。

　　(5)研讀規(guī)劃提供的程序，對(duì)邏輯雜亂的部分輸入、輸出點(diǎn)制造時(shí)序圖，一些規(guī)劃中的邏輯過(guò)錯(cuò)，在制造時(shí)序圖時(shí)即可發(fā)現(xiàn)。

　　(6)分子體系編制調(diào)試計(jì)劃，然后在團(tuán)體評(píng)論的基礎(chǔ)上綜合成為全體系調(diào)試計(jì)劃。

　　2、PLC商檢

　　商檢應(yīng)有甲乙兩頭共同進(jìn)行，應(yīng)承認(rèn)設(shè)備及備品、備件、技能材料、附件等的類型、數(shù)量、規(guī)范，其功用是否無(wú)缺待實(shí)驗(yàn)室及現(xiàn)場(chǎng)調(diào)試時(shí)驗(yàn)證。商檢成果，兩頭應(yīng)簽署交換清單。

　　3、實(shí)驗(yàn)室調(diào)試

　　(1)PLC的實(shí)驗(yàn)室設(shè)備與注冊(cè)制造金屬支架，將各作業(yè)站的輸入、輸出模塊固定其上，按設(shè)備提要以同軸電纜將各站與主機(jī)、編程器、打印機(jī)等相銜接，查看接線正確，供電電源等級(jí)與PLC電壓選擇相契合后，按開(kāi)機(jī)程序送電，裝入體系配置帶，承認(rèn)體系配置，裝入編程器裝載帶、編程帶等，按操作規(guī)程將體系注冊(cè)，此刻即可進(jìn)行各項(xiàng)操作實(shí)驗(yàn)。

　　(2)鍵入作業(yè)程序

　　(3)模仿I/O輸入、輸出，查看修正程序本進(jìn)程的意圖在于驗(yàn)證輸入的作業(yè)程序的正確性，該程序的邏輯所表達(dá)的工藝設(shè)備的聯(lián)鎖聯(lián)系是否與規(guī)劃的工藝操控要求相符，程序是否疏通。若不相符或不能工作完成全進(jìn)程，闡明程序有誤，應(yīng)進(jìn)行修正。在這一進(jìn)程中，對(duì)程序的了解將逐漸加深，為現(xiàn)場(chǎng)調(diào)試作好了準(zhǔn)備，同時(shí)也可以發(fā)現(xiàn)程序不合理和不完善的部分，以便進(jìn)一步優(yōu)化。

　　調(diào)試辦法有兩種：

　?、倌７罗k法：按規(guī)劃做一塊調(diào)試板，以鈕子開(kāi)關(guān)模仿輸入節(jié)點(diǎn)，以小型繼電器模仿生產(chǎn)工藝設(shè)備的繼電器與接觸器，其輔佐接點(diǎn)模仿設(shè)備工作時(shí)的回來(lái)信號(hào)節(jié)點(diǎn)。其長(zhǎng)處是具有模仿的真實(shí)性，可以反映出開(kāi)關(guān)速度差異很大的現(xiàn)場(chǎng)機(jī)械觸點(diǎn)和PLC內(nèi)的電子觸點(diǎn)相互銜接時(shí)，是否會(huì)發(fā)作邏輯誤動(dòng)作。其缺陷是需求添加調(diào)試費(fèi)用和部分調(diào)試作業(yè)量。

　　②強(qiáng)置辦法：使用PLC強(qiáng)置功用，對(duì)程序中觸及現(xiàn)場(chǎng)的機(jī)械觸點(diǎn)(開(kāi)關(guān))，以強(qiáng)置的辦法使其“通”、“斷”，迫使程序工作。其長(zhǎng)處是調(diào)試作業(yè)量小，簡(jiǎn)便，不需另外添加費(fèi)用。缺陷是邏輯驗(yàn)證不全面，人工強(qiáng)置模仿現(xiàn)場(chǎng)節(jié)點(diǎn)“通”、“斷”，會(huì)構(gòu)成程序工作不能連續(xù)，只能分段進(jìn)行。

　　依據(jù)我們現(xiàn)場(chǎng)調(diào)試的經(jīng)驗(yàn)，對(duì)部分重要的現(xiàn)場(chǎng)節(jié)點(diǎn)采納模仿辦法，其他的選用強(qiáng)置辦法，取二者之長(zhǎng)互補(bǔ)。邏輯驗(yàn)證階段要著重逐日填寫調(diào)試作業(yè)日志，內(nèi)容包含調(diào)試人員、時(shí)刻、調(diào)試內(nèi)容、修正記載、毛病及處理、交代驗(yàn)收簽字，以樹立調(diào)試作業(yè)責(zé)任制，留下調(diào)試的第一手材料。關(guān)于規(guī)劃程序的修正部分，應(yīng)在規(guī)劃圖上注明，及時(shí)征求規(guī)劃者的定見(jiàn)，力求準(zhǔn)確表現(xiàn)規(guī)劃要求。
 

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194E-E16-PE 194E Earthing-Grounding Terminal

2090-CFBM4DF-CDAF12 MP-Series 12m Feedback Cable

2090-KPBE7-06AA MP-Series Power and Brake Connector Kit

BC5005TBX0000 15 Inch Inbligence Industrial Computer - Bundled - Perbance Series - w/ Windows XP

GC646TRT050 Proficy GlobalCare Complete for Server 50 I/O RUNTIME SYS

HMI-BEZ-205 Stainless Steel Bezel: 12.1 inch (QPL2xxxx-C2P)/ NEMA 4X

IC641CTL931 Control 90-30 Programmer with Paper Documentation Library

IC647IEC005 IEC 61850 Client - 5000 points

IC660EBA020RR Ph B Analog 24/48Vdc 4 In/2 Out Electronic Assembly

IC695FTB1S132 Fiber terminal Block kit includes the IC695FTB001 base plus two IC694TBS032 high density extended shroud spring style terminal blocks

IC756WRE024J-28 Runtime License for Windows 1-24 Users, Per User, Japanese v2.8

FlexLogix System 1794-ADNK CONFORMALLY COATED, DEVICENET ADAPTER

PLC-5/1771 System D1771-6.5.85 PLASTICS MOLDING MODULE INJECT MODE MANUAL

Process Control 1757-PLXRT10 PROCESSLOGIX 10 USER REMOTE OPERATOR INTERFACE

Operator Interface 2711P-T7C4B2 PV PLUS 700, TOUCH, ENET, AC PS, EXT MEM

Support 9307-RSE32R SUPT REINSTATEMENT CONTRACT FOR 9307RSE32

Support GML-DAS SUPT RENEWAL CONTRACT FOR GMLDA

Support F1785-L20CSERE FIRMWARE UPGRADE FOR 1785-L20C PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300 RSVIEW32 WORKS 1500

RSI Software Products 9701-VWSB100JPU1 RSV SE STATION 25 - 100 DISPLAY UPGRADE (JAPANESE)

RSI Software Products 9399-INTDOSUG INTERCHANGE FOR DOS USERS GUIDE

Motion Control 2098-IPD-005-DN DRIVE, 2.5A/7.5A, ULTRA5000, DEVICENET

BC646MBPS99 ME Professional Dev. Suite Site License

IC300DIQ722 14 AC Inputs / 10 Outputs, 120 - 160 VAC Sink or source, Relay Out, 3 amps. isolated, 2 per common

IC752MNL003 Mature. Datapanel 1000 Series Operator's Manual

MTR-3S63-G-R-B-E-S MTR series servo motor with resolver and brake and shaft seal

ZA06B-6114-K213#E AHVis and AHVi Motor Brake Connector Kit (90 Deg)

20BP730N0NNNNNC0 PowerFlex 700 AC Drive 730 A 400 kW. 20B

20G1ABC540JN0NNNNN PowerFlex 755 AC Packaged Drive

25A-B2P5N104 PowerFlex 523 0.4kW (0.5Hp) AC Drive

2711P-T15C21D8S PanelView Plus 7 Standard 1500

OPC-F1-RS(RS485通信)

1492-JG3TW IEC 1-Ckt Feed-Thru Grd Blk 3 Conn Pts

1492-WG16S IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW44223BC36

性能信號(hào)模塊 6ES7 531-7KF00-0AB0 AI 8：模擬量輸入模塊，AI 8x U/I/RTD/TC ST, ( 支持 4 通道 RTD), 35mm 模塊，不含前連接器

156-B45CB1 45 A Contactor

1746-NI8 SLC 8 Point Analog Input Module

1787-RSCABL 6FT (1.82 M)9-9PIN NULL MODEM RS-232 CBL

193-T1DC90 72-90 A IEC Bibllic Overload Relay

20-IP54RF-600 ROOF, IP54/N12, FOR 600MM WIDE POWERFLEX

2090-CSBM1DF-14AF10 Kinetix Cable Single DSL 2090-Series

20AC022C0AYNANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GA647WFL000 Proficy GlobalAssist Complete for Proficy Workflow - Site License

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IC600CP610RR 13 inch Series Six Plus CPU w/o Power Supply (8 Slots)

IC647HSTCSEO20000KM eSignature Option for Historian - Enterprise Corporate Server 20,000,000 Points (M4 Key)

IC647WFL010 Proficy Workflow - 10 User License

IC694ALG220 Input module, analog 4 point voltage.

IC756RDV010E-98 DV Draw Development on IRIX Op Sys, English, Version 9.8

MicroLogix 1200 System 1762-MM1RTC MEMORY MODULE WITH RTC

PLC-5/1771 System 1771-LIA LOOP CONTROLLER INTERFACE MODULE

Distributed I/O 1794-OA8 85-132 VAC OUTPUT MODULE, 8 POINT

Communications 9355-WABPTE RSLINX PRO - PORTUGESE

Operator Interface D6195-6.5.4FR CONTROL/VW & CONTROL/VW 300 RUNTIME REF MNL FRENCH

Support 9358-BERP02R SUPT REINSTATEMENT CONTRACT FOR 9358BERP02ENE

Support F1771-ACN15SERB FIRMWARE UPGRADE FOR 1771-ACN15 PROCESSOR

RSI Software Products 9324-RL03U7ENE RSLOGIX 500 STD TO PRO UPGRADE

RSI Software Products 9301-2SE350DEU4R RSVIEW32 RUNTIME 150-100K UPGRADE OUT-SUPT (DE)

RSI Software Products 9358-HSTS2350U1 UPGRADE: IN-SUPT: HISTORIAN 150 TO 5K TAG

Motion Control W-4050-P-H00AB MOTOR,SERVO,WASHDOWN,BF,5.4 NM,3000RPM,14.1KG

612A-FT-SI-N4 Numeric Keypad Entry, 4 Digit LED DISP., Full Travel Keys. Sinking Output, NEMA 4

IC200MDD842LT MIXED 24VDC POS LOG OUTPUT 0.5A GRP WITH ESCP 16PT / INPUT GRP 16PT (LT)

IC695STK002 Includes RX3i and QuickPanel View 6 inch STD with software (one each IC695CPU310/ IC695CHS012/ IC69 5LRE001/ IC695PSA040/ IC695ETM001/ IC694ACC300/ IC694MDL940/ IC754VSI06STD/ BC646MQP001/ IC646MPP001 and DC power)

MTR-1220-N-A-E-0RR Stepping Motor Nema23

Z44A718031-G05 Alpha i-series servo bus bar kit for 60 mm wide module

20BD077A0AYNAND0 PowerFlex 700 AC Drive 77 A 60 Hp 20B

20G11NC022AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-B025N104 PowerFlex 4M- 5.5 kW (7.5 HP) AC Drive

990NAD23010 Quantum MB+ TAP接頭,RUGGEDIZED

29340-018-01-R M8-1.25 HEX NUT STYLE 1

Y92F-30 面板安裝夾，

1492-SPM2D500 MCB Supplementary Protector 50 A

軟啟動(dòng)器 3RW40242TB05

電機(jī)啟動(dòng)器 3VU16401CR00

150-F361NCD SMC Flex Smart Motor Controller