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本文介紹了西門子 S7-200 SMART PLC、SMART LINE 觸摸屏以及 SINAMICS V20 變頻器在套標機上的應(yīng)用，闡述了設(shè)備工藝流程、控制系統(tǒng)的配置選型、軟件設(shè)計和實現(xiàn)的功能。經(jīng)測試，該方案能完全滿足高速套標機的各項技術(shù)要求，運行穩(wěn)定，性能良好。
　　關(guān)鍵詞：S7-200 SMART SMART LINE SINAMICS V20 套標機
1 引言
　　套標機是一種將熱縮塑膠商標桶卷自動切斷，準確套入容器的包裝機械，配合后熱收縮工序，將標簽完好地固定于容器適當(dāng)位置。
　　上世紀 90 年代以來，我國的快速消費品包裝工業(yè)得到了迅速發(fā)展，快速消費品企業(yè)的生產(chǎn)集中度和自動化程度在不斷提高，包裝設(shè)備在向大型化、快速化、高效化、自動化方向發(fā)展。套標機作為后段包裝技術(shù)含量較高的設(shè)備之一，其優(yōu)良的高速穩(wěn)定性能，獨特的靈巧化設(shè)計，人機協(xié)和的安全模式，得到了廣大客戶的充分肯定。套標機的使用大大降低了套標環(huán)節(jié)的人力物力，現(xiàn)已廣泛應(yīng)用于啤酒飲料、化工、醫(yī)藥等行業(yè)。
2 套標機工藝原理
　　2.1 套標機結(jié)構(gòu)
　　從工藝功能的角度進行劃分，套標機的結(jié)構(gòu)可分成以下 9 單元。并如圖 1 所示。
　　(1) 供料組：由變頻器帶動供料電機旋轉(zhuǎn)，用以傳送標簽?zāi)ち?
　　(2) 電眼架組：使用光纖電眼傳送信號，提供下標伺服做定尺寸輸送，電眼位置可高低調(diào)整;
　　(3) 驅(qū)動組：采用雙驅(qū)送料機構(gòu)，由下標伺服電機驅(qū)動。用于固定中心柱和下標動力傳動;
　　(4) 刀盤組：采用同步輪機構(gòu)，由伺服電機驅(qū)動，當(dāng)進瓶光電 7 給出信號時，切刀電機帶動刀片旋轉(zhuǎn)一周將標簽切斷;
　　(5) 刷下組：采用同步調(diào)整機構(gòu)，將刷下兩組傳送輪調(diào)整至中心柱下方與滾輪輕微接觸，待標簽通過時以較高轉(zhuǎn)速將標簽套入瓶子;
　　(6) 分瓶螺桿：將欲套標瓶做等距分開，進入帶瓶組，速度由變頻器控制，與輸送帶同步;
　　(7) 照瓶電眼：檢測是否有瓶子通過，當(dāng)有瓶子經(jīng)過時輸出訊號使切刀開始旋轉(zhuǎn)，左右位置可以調(diào)整;
　　(8) 輸送帶：使用變頻器調(diào)整輸送帶速度，以適用于各產(chǎn)能的速度匹配;
　　(9) 帶瓶組：采用兩側(cè)同步傳動，標簽高低與夾瓶定位各一只手輪調(diào)整，目的使瓶子輸送時不搖晃和控制套標簽高度，速度由變頻器控制，與輸送帶同步。
　　2.2 套標機工藝流程
　　當(dāng)輸送帶上有瓶子經(jīng)過照瓶電眼時，由伺服控制的切標電機會將標簽切斷，切標完成后下標伺服電機開始動作，等到光纖信號到來時停止送標，同時刷下料輪會將已經(jīng)切斷的標簽刷下套入瓶子上，完成一次動作。具體工藝流程如圖 2 所示。
硬件系統(tǒng)設(shè)計
　　3.1 硬件系統(tǒng)分析
　　本系統(tǒng)需要兩路高速脈沖輸出，分別控制切刀和下料伺服;一路高速計數(shù)器，用于控制切刀停止的位置，切刀停止位置應(yīng)不影響下標的動作，否則會造成堵標。
　　以往套標機的調(diào)速方式普遍采用電位器控制，用三個電位器分別控制輸送帶電機，定位皮帶電機和螺桿電機，供料電機的速度因為不經(jīng)常調(diào)節(jié)，所以用變頻器本身自帶的電位器調(diào)速。每次輸送帶速度變更時，都需要重新調(diào)節(jié)螺桿和定位皮帶的速度。調(diào)節(jié)時主要依靠調(diào)試人員的技術(shù)經(jīng)驗和不斷的放瓶測試，才能使其線速度基本同步。本項目中設(shè)備的 I/O 清單如表 1 所示。
　　3.2 硬件系統(tǒng)設(shè)計
　　在本項目的電控方案中，選用西門子 SMART 解決方案，包括 S7-200 SMART PLC、SMART LINE 觸摸屏和 SINAMICS V20 變頻器。根據(jù)上述 I/O 需求，總共 12DI/12DO，選用 CPU ST40(24DI/16DO) 即可滿足需求。 SINAMICS V20 變頻器通過 USS 協(xié)議與 PLC 進行通訊，不僅控制更加方便，也節(jié)省了 PLC 的 I/O 點。通過計算可將電機角速度轉(zhuǎn)化為輸送帶線速度。PLC 和觸摸屏通過以太網(wǎng)進行通訊，只需要在觸摸屏上輸入生產(chǎn)速度，其他電機將會自動進行線速度同步。該方案大大縮短調(diào)試時間，降低調(diào)試難度。硬件結(jié)構(gòu)如圖 3 所示，主要硬件配置表如表 2 所示。
4 軟件系統(tǒng)設(shè)計
　　4.1 運動控制配置
　　S7-200 SMART 集成了三路 100kHz 的高速脈沖輸出，在本系統(tǒng)中切刀伺服占用 Q0.0，下標伺服占用 Q0.1。打開 Micro/WIN SMART 集成的運動控制向?qū)?，配置軸 1 和軸 2，選擇單向相對脈沖，最大速度 50K，最小速度 1K，加減速時間 30ms，然后生成子程序。
　　4.2 高速計數(shù)配置
　　S7-200 SMART 集成了 4 路高速計數(shù)器，在本系統(tǒng)中只使用了高速計數(shù)器 HSC0，用于接收切刀的脈沖輸出，占用輸入點 I0.0。打開 Micro/WIN SMART 集成的 HSC 向?qū)?，配?HSC0，選擇工作模式 0，預(yù)設(shè)值為 80000，當(dāng)前值為 0，計數(shù)方向向上，勾選 PV=CV 時中斷，步數(shù) 1，然后生成。當(dāng)切刀伺服啟動后檢測到刀盤原點光電時，利用外部中斷快速更新高速計數(shù)器 HSC0 的當(dāng)前值和目標值，目標值等于當(dāng)前值加上偏置值。PV=CV 中斷時停止脈沖輸出，同時啟動下標伺服。
　　4.3 USS 通訊
　　S7-200 SMART 自帶庫文件 USS 協(xié)議，只需調(diào)用 USS 功能塊即可實現(xiàn) PLC 與西門子變頻器的通訊。通過 USS_INIT 進行通訊參數(shù)初始化設(shè)置，包括與變頻器通訊的波特率，激活的變頻器個數(shù)，所占用的端口等，通信參數(shù)必須與變頻器設(shè)置的一致，否則無法通訊。每次通信參數(shù)的更改都需要重新執(zhí)行此命令，本項目中的通訊參數(shù)固定，所以只上電執(zhí)行一次。通過調(diào)用 USS_ CTRL 指令可以直接控制變頻器的啟動、停止以及頻率，每條 USS_CTRL 指令只能控制一臺變頻器。
　　4.4 SINAMICS V20 變頻器的配置
　　設(shè)置V20變頻器的連接宏為Cn010—USS控制，分別設(shè)置螺桿、皮帶、供料、輸送帶變頻器地址 P2011[0] 為 1、2、3、4。同時，設(shè)置應(yīng)用宏為 AP030—傳送帶控制，SINAMICS V20 可自動配置適合傳送帶應(yīng)用的控制參數(shù)。
 

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RSI Software Products 9301-2SE2400U5 UPGRADE: IN-SUPT: RSVIEW32 WORKS 5000 TO 32000

RSI Software Products 9357-ENETMD3E RSNETWORX WITH MD FOR ENET

Motion Control MPL-A420P-MJ22AA MOTOR,SERVO,4.74 NM,5000RPM,MULTI,230V,5.0KG

Motion Control 2090-UXNFBN-K03 CABLE,ULTRA, NON-FLEX,SKWD,R/A,3M

CBL-13-ET-20 MTR-1300 and MTR-1N Series Stepping Motor Encoder Feedback Cable, 20 Ft.

IC600WD500 I/O Cable, 500 feet (150m)

IC800SKCPZ050 Power Cable, S2K to 200 - 750W S-Series Servo Motors, 5 Meters

OC647IFGLBLCLN001M iFIX WebSpace: Additional 1User

20AD1P1A3AYNAEG0 PowerFlex 70 AC Drive 20A

20DC8P7A0EYNANAEE PowerFlex 700S AC Drive 8.7 A 4 kW 20D

20P21AD129RA0NNN PowerFlex 129 A DC Drive

2711-ND3FRM PanelView ND3FR MED Accessory

280-PWRM22G-M10 ArmorStart Three-Phase Power Media

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6ES7 355-0VH10-0AE0 帶4個模擬輸出的四通道閉環(huán)控制模塊 FM355C

KCPI-3130

IPC-586VDH

SHT-16B-CT/CPCI

PROx 1603-G3A

3C900B-COMBO

CAN-PCI/200

DALSA VA50E-04

1492-SPM3B320 MCB Supplementary Protector 32 A

軟啟動器 3RW40372BB15

BC646EXO365 Solution Provider additional OP License

GC646TRT935 Proficy GlobalCare Complete for Server 35,000 I/O Runtime System

HMI-CAB-C102 CABLE MODICON 984 MICRO

IC641GTE666 Diagnostics/Configuration Disk for IBM-PS/2 Class Computers

IC647IFCLNTCRNC iFIX iClient Runtime (M1Component Part)

IC660EBA024RR Current Source Analog, 24/48Vdc, Electronic Assembly

IC695MDL765 Smart Digital Output Module 24/125 volt DC, ESCP 1A Positive Logic 16 Points. Module does not ship with terminal block. IC694TBB032 or IC694TBSx032 terminal block is required.

IC756WRE049E-23 DataViews Runtime for Windows 25-49, Per User, English, Version 2.3

FlexLogix System 1794-IA8I 85-132VAC INPUT MOD(ISOL)

PLC-5/1771 System D1771-6.5.92 1771-BIM BASIC MODULE USER MANUAL

Process Control 1757-PLXSIFD PLX HW S9000 ETHERNET QUICKBUILDER INTERFACE

Operator Interface 2711P-T7C6D2 PV PLUS 700, TOUCH, RIO/DH, DC PS, EXT MEM

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Support GML-DSS SUPT RENEWAL CONTRACT FOR GMLDS

Support F1785-L26BSERD FIRMWARE UPGRADE FOR 1785-L26B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300ESU2 RSVIEW32 WORKS 150-1500 UPGRADE IN-SUPT (ES)

RSI Software Products 9701-VWSB250DEU1 RSV SE STATION 25 - 250 DISPLAY UPGRADE (GERMAN)

RSI Software Products 9399-INTWINUG INTERCHANGE FOR WINDOWS USER GUIDE

Motion Control 2098-IPD-HV030-DN HIGH VOLTAGE DRIVE, 7A/14A, ULTRA5000 DEVICENET

BC646MDA000 View Development/Runtime 8,000 I/O

IC300DQM902 20 Relay Outputs (250vac, 30vdc, 2.0A)

IC752PBMU11 Profibus Master/Scanner for ControlStation CE Iix

MTR-3S65-G-R-B-E-SRR Servo Motor 24V Brake, Seal

ZA06B-6114-K230#E Motor power right angle connector for B0.4/5000is or B0.5/5000is or B1/5000is or BM0.5/4000 or BM1/4000 motor

20C-DA1-A PowerFlex 700H 24V DC Control IO Board

20G1ABC770AN0NNNNN PowerFlex 755 AC Packaged Drive

25A-D010N114 PowerFlex 523 4kW (5Hp) AC Drive

2711P-T15C4A8 PanelView Plus Terminal

6SE6440-2UC17-5AA1 0.75KW

SC-N5 380VAC/105A 55KW 110V . 220V AC 2NO+2NC

UG221H-TC4 5.7寸 TFT 16色 320*240 24VDC

SCC-AI04

PROFIBUS-PC

MRT-6320P-R

CORECO iMAGING X64-AN OC-64A0-02040

PCM-087

PWA 91\262C

1492-SPM1C040 MCB Supplementary Protector 4 A

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20AC030A0AYYANC0 PowerFlex 70 AC Drive 30 A at 15 kW 20A

GC-8455-SW-CF MTL8000 Configurator Software (Serial cable included)

GPA-602-PCI LVDT b system for PCI (End User).

IC600CR620RR 19 inch Series Six Plus CPU Rack w/o Power Supply (11 Slots)

IC647HSTCSEO500KM eSignature Option for Historian - Enterprise Corporate Server 500000 Points (M4 Key)

IC647WFLPCA Proficy Workflow - Production Corrective Action Templates and Reports

IC694ALG223CA Input module, analog 16 point single ended, current.

IC756RDV010K-99 DV Draw Development on IRIX Op Sys, Korean, Version 9.9

MicroLogix 1200 System 1762-OW16 16 POINT VAC/VDC RELAY OUTPUT MODULE

PLC-5/1771 System 1771-QA STEPPER MOTOR POSITIONING ASSEMBLY W/ 1771OJ,-M1