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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)，并對現(xiàn)場經(jīng)常出現(xiàn)的設(shè)備、調(diào)試相關(guān)問題，提出評論定見和解決計(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、對體系工藝流程，特別是工藝對各生產(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)備的操控與動力接線圖，并與什物相對照，以及時(shí)發(fā)現(xiàn)過錯(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)號表(包含內(nèi)部線圈一覽表，I/O所在位置，對應(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，其功用是否無缺待實(shí)驗(yàn)室及現(xiàn)場調(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，供電電源等級與PLC電壓選擇相契合后，按開機(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，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，對程序的了解將逐漸加深，為現(xiàn)場調(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)的回來信號節(jié)點(diǎn)。其長處是具有模仿的真實(shí)性，可以反映出開關(guān)速度差異很大的現(xiàn)場機(jī)械觸點(diǎn)和PLC內(nèi)的電子觸點(diǎn)相互銜接時(shí)，是否會發(fā)作邏輯誤動作。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，對程序中觸及現(xiàn)場的機(jī)械觸點(diǎn)(開關(guān))，以強(qiáng)置的辦法使其“通”、“斷”，迫使程序工作。其長處是調(diào)試作業(yè)量小，簡便，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)場節(jié)點(diǎn)“通”、“斷”，會構(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)場調(diào)試的經(jīng)驗(yàn)，對部分重要的現(xiàn)場節(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，力求準(zhǔn)確表現(xiàn)規(guī)劃要求。
 

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20-PP12001 OPTICAL FIBER SET

2090-CSBM1DF-18AF11 Kinetix Cable Single DSL 2090-Series

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GC646MBP001 Proficy GlobalCare Complete for ME Professional Development Suite

HE670IBU100 Discontinued Part. Check with GE IP on migration path.

IC600LX680RR 64K Logic/16K Register Memory Module

IC647HSTESEO100KM eSignature Option for Historian - Enterprise Server 100000 Points (M4 Key)

IC655CCM500RR Communications Control Module (CCM)

IC694MDL230 Input module, 120 VAC 8 point, isolated per point.

IC756SDV001K-99 DV Development - Solaris Op Sys Addt'l User, Korean, Version 9.9

MicroLogix 1500/1769 System 1769-IQ16 16 POINT 24 VDC SINKING/SOURCING INPUT MODULE

PLC-5/1771 System 1785-KA5 COMMUNICATION MODULE DATA HWY PLUS TO DATA HWY 485

Distributed I/O 1794-TB3G 3-WIRE GROUNDED TERMINAL BASE - SCREW CLAMP

Communications 9399-WABUG WINTELLIGENT LINX FOR A-B PROG. CONTROL USER GUIDE

Support 9311-PASJR 9311PASJ SOFTWARE SUPPORT CONTRACT REINSTATEMENT

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RSI Software Products 9324-RLD0U7PTE RSLOGIX 5000 SERVICE ED TO PRO UPG, PTG

RSI Software Products 9301-OPCSRVENE KEPSERVER ENTERPRISE

RSI Software Products 9358-PLTM2200ENE RSBIZ PLNTMET SEV 10 BELL

Motion Control 8720SM-022S2GAS2 22 KW/48 AMP, 750VDC, AC MOTOR WITH SRM60 ENC.

840-RC-15 15" Ribbon Cable. Term Both Ends W/16 Pin DIP Plugs

IC200MDL940 OUTPUT RELAY 2.0A PER PT ISOLATED FORM A 16PT

IC697VAL314 Analog Output, Isolated, 4 channel, 12 bit, Current - 4 to 20mA. Removable temrinal block, no cable required

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ZA06B-0062-B503 B2/4000HVis servo motor with 24 VDC brake and 128k serial encoder

20BD156A3ANNANC0 PowerFlex 700 AC Drive 20B

20G11NE011AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-V6P0N103 PowerFlex 4M-1.1 kW (1.5 HP) AC Drive

140CFI00800 Quantum CABLEFAST, 模擬量輸入塊, 無保險(xiǎn)

294E-FD2P5Z-G1 Variable Frequency Drive

HL-5030 觸點(diǎn):1開/1閉,5A 250VAC機(jī)械壽命:1000萬次?撞壓式 可調(diào)滾珠擺桿型

1492-SPM3B500 MCB Supplementary Protector 50 A

軟啟動器 3RW40372BB04

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150-F85NBRB SMC Flex Smart Motor Controller

1734-IT2I POINT I/O 2 Point Thermocouple Input

1783-HMS16TG4CGN Stratix 5400 20 Port Managed Switch

193-ER1A Remote Reset Solenoid

20-750-EMCBUS1-F8 PF750,FR8,IP00,EMC BUS, TERMINATION KIT

2090-CPWM7DF-14AA03 MP-Series 3m SpeedTec Standard Cable

2098-DSD-075-SE Ultra 3000 Servo Drive

GA646IFCLNTCRO100 GCA iFIX iClientTS Read Only 1 PK Runtime Version

GFK-2222 PACSystems CPU Reference Manual

IC220TBK123 I/O TERMINAL STRIP, 12 POSITION SPRING STYLE, OUTPUT, QTY 10

IC647GE9C GE9:GE Fanuc Ethernet

IC647SGM001 Scheduler Series and Groups Module

IC693MDL646CA Conbal Coated Input module 24 VDC 16 point POS/NEG ogic. 1msec filtering.

IC756DVE010K-99 EO GECK (Graphical Editor Construction Kit) - Inb x87, Korean, Versi on 9.9

MSI-QUAL-UNL-43 Unltd Site Clients - Quality Mang-43

PLC-5/1771 System 1771-DS LATCHING INPUT MODULE, 10-27V DC, 8 INPUTS

Distributed I/O 1790D-N0C2 DNET LDX, 2 OUTPUT ANALOG CURRENT BSE,D-SHELL CONN

Communications 1770-XE DATA HWY 15 PIN CONNECTOR KIT, (FEMALE)

Operator Interface 2727-M7P20D1Q3 MOBILEVIEW MACHINE TERMINAL MT750

Support 9305-RSVADFCPTR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADFCPT

Support 9515-RSAAMRCTS SUPT RENEWAL CONTRACT FOR 9515RSAAMRCTENE

EtherNet/IP Products 2706-P44R INVIEW MESSAGE DISPLAY. 1 OR 2 LINE

RSI Software Products 9301-2SE3400PTU5 RSVIEW32 RUNTIME 5K-32K UPGRADE IN-SUPT (PT)

RSI Software Products 9515-RSCMP075ENE RSGUARDIAN MIGRATION PROMOTION, <=75 DEVICES

Motion Control 1326AB-B430G-S2L MOTOR,SERVO,460V,6.4NM,5000RPM,SINGL,IP67

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IC693BEM331 Genius Bus Controller

QPLCTAE0000 12.1" Color TFT, Ethernet, CF Card, 110VAC

TGT-E00A-2-0RR Target Axis Expansion Module, 3' Rack Linker Cable