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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(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(dòng)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(hào)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(hào)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(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(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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1734-OV2E POINT I/O 2 Point Digital Output Module

1794-CE3 Flex Extension Cable

188-K3D630 Miniature Circuit Breaker 63 A

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Industrial Computers 6189V-MRA17 RACK ADAPTER FOR 17" PLATFORMS

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DeviceNet Products 1792D-4BVT4D 4 SINK/SOURCE INPUTS, 4 SOURCING 0.5 AMP OUTPUTS

RSI Software Products 9301-2SE320JPU1R RSVIEW32 RUNTIME 150-300 UPGRADE OUT-SUPT (JP)

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Motion Control MPL-B4530K-MJ22AA MOTOR,SERVO,8.36 NM,4000RPM,MULTI,460V,8.2KG

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194L-E25-1753 25 A 194L Load Switch

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2090-XXNFMP-S15 MP-Series 15 m Length Feedback Cable

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IC697MEM715RR Expansion RAM, 128 KBytes,CMOS (Used w/77X CPUs & PCM)

IC800SSD228RS1 28 amp 230 VAC S2K servo drive for MTR series motors

ControlLogix/1756 System D1756-UM058CENP CONTROL LOGIX DIGITAL I/O MODULES USER MANUAL

Industrial Computers 6182H-15KRH4D VVCE 1500, KEYPAD, STD MEM, ENET, DC

Process Control 1757-DNBUL50 DEVICENET USAGE LICENSE, 50 DNB MAX

Operator Interface 2711-START300DE START KIT PV300 KEY,GERMAN(PV300,PB32, CABLES)

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ControlNet Products 1797-TPR CONTROLNET EX T-TAP RIGHT ANGLE

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RSI Software Products 9358-BA60U1R UPGRADE: OUT-SUPT: RSBIZWARE ARCHIVER 03 TO 60

Motion Control MPL-A4520P-HJ22AA MOTOR,SERVO,6.10NM,5000RPM,ENCDR,230V,6.8KG

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IC640MWS901RR Workmaster System, 1-35" Disk Drive

IC800SLCS020 Cable, SL Amplifier Serial Communication, 2 Meters

OC647IPWRCLNRNM iPower Option - Run Client

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W26361-W64-Z2-06-36

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1492-MCBA2H80 80A Miniature Circuit Breaker

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1585D-M8UGDM-4 Gigabit Ethernet Media

1756-L74K ControlLogix 16 MB Controller

1799-DNETSCN2R Embedded I/O DeviceNet Connector

194E-FA32-P11 194E Load switch

2090-CFBM7DD-CEAA20 MP-Series 20m Servo Feedback Cable

2090-SCVP5-0 Kinetix 5-5m Fiber Optic Cable

BC646MPS010 Logic Developer PLC Standard 10 Pack with Proficy GlobalCare Complete

GC647AQC010 GC Quality Client 10 Pak

HMI-COV-202 FRONT SHEET COVER FOR 10.5 inch (QPI2xxxx-C2P/ - L2P/ -S2P)/ 10 per pack

IC641VPS325 VersaPro Standard Edition 25 Pack - Windows Programming Software for S eries 90-30 and VersaMax PLCs

IC647IFPLDV00150K iFIX Plus SCADA 150 I/O Development (M1 Kit Part)

IC660ELB906RR PCIM Module and S/W Drivers

IC697ACC729 Top and Bottom PWA Cover - I/O Link

IC756WRT499E-26 DV-Tools Runtime Windows, Eng v2.6

FlexLogix System 1794-IJ2K CONFORMAL COAT, 2-CHANNEL HI RES FREQUENCY MODULE

PLC-5/1771 System D6200-6.5.17 AGA CAR(CAT.NO.6200-AGA5)PROGRAMMING MANUAL

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PCM-5111

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1747-CP3 SLC 5/03 Programmer RS-232 Cable

1790D-T8BV8B CompactBlock LDX 16 Point Base Block

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HE693BZL100 Mounting bezel for compact OIUs.

IC600PM546RR CPU/DPU Power Supply, 125Vdc

IC647HSTESEO300M eSignature Option for Historian - Enterprise Server 300 Points (M4 Key)

IC655MDL552RR 12-24Vdc Output, Negative Logic (32 points)

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MicroLogix 1500/1769 System 1769-OW8I 8 PT. VAC/VDC INDIV. ISOLATED RELAY OUTPUT MODULE

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Support 9313-PLC3R SUPT REINSTATEMENT CONTRACT FOR 9313PLC3

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RSI Software Products 9324-RLD2U3ENE RSLOGIX 5000 MINI TO STD UP, ENU

RSI Software Products 9304-WTD300D RSTREND

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MTR-1337-N-D-E-0RR Stepping Motor Nema34

NI 5772

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NANO-945GSE2-N270W-R10

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1492-SPM3C040-N MCB Supplementary Protector 4 A

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150-FPP43B SMC Flex Repair Part

1734-OB8S 8 Channel Safety Sourcing Output Module

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193-ESM-I-30A-P E300/E200 30 Amp Sensing Module

20-750-FLNG1-F5 PowerFlex 750 NEMA 1 Flange Adaptor Kit

2090-CPWM7DF-14AA90 MP-Series 90m SpeedTec Standard Cable

2098-DSD-HV050 Ultra 3000 Servo Drive

GA646PCMS1C GlobalCare Assist for Change Management Electronic Signature Module 100 Pack

GP-0602NT-F13 GagePort LVDT NT (Full Bridge for Schaevitz LBB 100 Series)

IC5002CAC0001 12in Inbligence PanelClient w/ iFIX TS

IC647HSTAE1000KM Alarm and Events Option for Historian - Standard Server 1,000,000 Points (M4 Key)

IC647SIEC SIE:Siemens 3964r

IC693MDL655RR 24 Vdc Input, Neg/Pos Logic, 1 ms, (32 pts), requires (2) CBL310

IC756HDV000K-99 DV Development - HP/UX Op Sys, Korean, Version 9.9

MSI-SDK-10 SDK Connections 10 Pack

PLC-5/1771 System 1771-ICD INPUT MODULE, 20-60V DC, 16 INPUT

Distributed I/O 1790P-TN0C2 PROFIBUS,2 OUTPT ANALG CURRENT BASE,TERMINAL BLOCK

Communications 1784-CP3 CABLE ASSY, 10 FT/3.20 M, 1784-KTP, -KT, -KT2, -KL

Operator Interface 2727-TRA7 MOBILEVIEW AC ADAPTER

Support 9305-RSVADSDER SUPT REINSTATEMENT CONTRACT FOR 9305RSVADSDE

Support 9515-RSCHM500S SUPT RENEWAL CONTRACT FOR 9515RSCHM500ENE

EtherNet/IP Products 2711-B5A20L1 PV550 MONO KEY&TOUCH, ENET & RS232 PRINT

RSI Software Products 9301-2SE3400ZHU3 RSVIEW32 RUNTIME 150-32K UPGRADE IN-SUPT (ZH)

RSI Software Products 9515-RSNHS050ENE RSMACC NETWORK HEALTH FOR 50 NETWORKS

Motion Control 1326AB-B520E-S2L MOTOR,SERVO,460V,13.0NM,3000RPM,SINGL,IP67

4161-4-24+/-N12 BCD To 7 SEG Display . 3 Numeric Digits & 1 +/- Digit, 24VDC. NEMA 12

HMI-CAB-C89 CABLE SATTCON 05-35

IC693CBL324 Cable, Terminal Board Connections for DSM302, 1 Meter

QSI31200S2P QUICKSTART KIT 10.5" STN

TRM-21006667 20 point connector for S2K digital I/O

AIMB-212D

PCI-7224

Matrox Y7007-02

Inb EXPI9301CTBLK 893647

FPCA-852GM

8001-4105

1492-SPM1C160 Mcb Supplementary Protector 16 A

通用型變頻器 6SE6 430-2UD33-7EB0 "37 KW,275 x 650 x 245"

電機(jī)啟動(dòng)器 3VU13401NK00

150-C16NCR SMC-3 16A Smart Motor Controller

1608P-200A380V4S 200 A Pro DySC Sag Corrector

1769-SM1 PowerFlex-SCANport To Compact IO module

193-CBCT1 E3 Plus Ground Fault Current Sensor

194R-R5 Operating Shaft

2090-CPBM7E7-08AF05 5 m Length SpeedTec Extension Cable

2090-XXTPMP-16S20 MP-Series 20 m Length Power Cable

CP3I-0WPB-0070-AZ Motor power cable with straight connector for A8HVis/A12HVis/B8HVis/B12HVis. 7 meters

GF-905694 Connecting FlashCable to Mitutoyo Angled Connection (LEFT).

IC200UER016 VersaMax Micro Expansion 16 Output Expansion (16) Relay Outputs, 24VDC Power Supply (includes IC200CBL501).

IC647ADC001 PA Dashboard Client

IC647PCL025 Proficy Process Systems Standard Edition Single Node 250 I/O with Cimplicity

IC693CBL305 Cable, Port Expansion, Used With PCM301, PCM311, and CMM311

IC754ACC12ADP 12 inch QP View-Ctrl to CEIIx Cut-out Adaptor Kit (Qty 10 Kits)

IMC-316D-X-D 6 amp IMC servo motor controller with Devicenet

SLC/1746 System 9399-CCDUG CONTROLGUARDIAN DETECTOR5 USERS GUIDE

Open Automation Systems 1789-STRT1DE SOFTLOGIX 5800 STARTER KIT GERMAN

Application-specific products 1404-M805A-232 MASTER MODULE-PQ 232 COM-120/240V P/S

Operator Interface 2711-K10G15L1 PV1000 GRAYSCALE KEY, CNET & RS232 PRINT

Support 9301-2SE3300JPR SUPT REINSTATEMENT CONTRACT FOR 93012SE3300JP

Support 9381-P15KENS SUPT RENEWAL CONTRACT FOR 9381P15KEN

DeviceNet Products 1792D-CBFM MAXUM MEDIA BASE FOR KWIKLINK FLAT MEDIA

RSI Software Products 9301-2SE3300ITE RSVIEW32 RUNTIME 1500 (ITALIAN)

RSI Software Products 9358-EP30U2 UPGRADE: IN-SUPT: RSBIZWARE EPROCEDURE 10 TO 30

Motion Control MPL-B4540F-MK22AA MOTOR,SERVO,10.2 NM,3000RPM,MULTI,460V

Motion Control 9101-0326 CONNECTOR KIT, MOTOR POWER, F/H-4X, STRAIGHT

GQPI3D200C2P QUICKPANEL COLOR 10.5" TFT GE LABEL

IC646MRB075 Logic PC 75 Tag Runtime System

MTR-1N41-G-N-A-E-0 Stepping Motor Nema42, Parallel Wdg

SA07-018 Industrial Application Server (4 days)

PXIe-6555

PCI-1603