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在企業(yè)搬遷工作中，原來(lái)在包裝崗位有兩臺(tái)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(hào)產(chǎn)品已經(jīng)被淘汰，而在搬遷后發(fā)現(xiàn)，PLC上電無(wú)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(duì)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(duì)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(jì)
　　針對(duì)本系統(tǒng)的特點(diǎn)，適合采用集成了IO點(diǎn)的小型PLC。而溫度可以單獨(dú)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(shí)，PLC通過(guò)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(jì)
　　根據(jù)現(xiàn)場(chǎng)設(shè)備匯總需要輸入點(diǎn)13個(gè)，輸出點(diǎn)12個(gè)，使用 S7-200 SMART系列的SR40型號(hào)CPU并設(shè)計(jì)IO表。
　　2.3 其它主要電氣設(shè)備選型
　　另外選擇了1臺(tái)安川V1000變頻器和2臺(tái)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(guò)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(guò)查找發(fā)現(xiàn)組態(tài)王已經(jīng)更新了S7-200 SMART的驅(qū)動(dòng)，驅(qū)動(dòng)名稱：S7 TCP.DLL，驅(qū)動(dòng)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(dòng)作最為復(fù)雜，而且各動(dòng)作也存在著邏輯關(guān)系，為了準(zhǔn)確執(zhí)行各封切動(dòng)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

Singer CSM-1 Communication Service Monitor

SIEMENS 6SN1111-A0B00-0AA0

SIEMENS LT Module 6SN1123 1AA00 0EA0 Version E Int 80 A

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SIEMENS 6FC5-210-0DA20-2AA1 MAIN MEMORY CONTROL UNIT MMC 103. 32MB DRAM

Advantech PCM-9370

ALLENBRADLEY1771OD16ISOLATEDOUTPUTMODULE

Allen Bradley SLC-500 Output Mod. 16-Point 1746-OA16

ABB PC-D232 3BHE022293R0101

Zygo ZMI-2002 Measurement Board 8020-0211-01-J Rev.L

.. Square D 800A Fusible Main Switch Cat# QMB367MW ... X-53

MODICON AS-506P-F12 NSFP AS506PF12

ALLEN BRADLEY 1394C-SJT22-A NSFP 1394CSJT22A

GETTYS 110-094-2 NSFP 1100942

GE FANUC 44A751082-012R01 USPP 44A751082012R01

SIEMENS 6SC9111-2AJ25 USPP 6SC91112AJ25

SIEMENS 1FT6064-6AC71-3EG1 NSFP 1FT60646AC713EG1

ADEPT TECH 10315-00940 USPP 1031500940

Siemens 6es5 905-3RB11 Simatic S5-105R ZB/CPU

Siemens S5 6ES5 458-7LC11 Relay Output Module

SIEMENS 6ES5465-4UA12 6ES5 465-4UA12S5 465-4 Analog Input WARRANTY

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Schneider Modicon AS-B885-100 ASB885100 Motion Module

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SIEMENS 6ES7 321-1BL00-0AA0 SIMATIC S7 INPUT MODULE

SANS DIGITAL MR4UT 4-bay hot-swap hardware RAID storage

Siemens Genumerik 3G Board GE.548 190.0001.00 GE548190000100 GE54819OOOO1OO

SIEMENS Sinumerik 805 6FC4100-1AA00-Z Free Ship

SIEMENS 6AV1222-0AD20 Communications Processor Module R6AV1222-0AD20

SIEMENS 6SN1145-1BA00-0CA0

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Allen-BradleyPanelView1000OperatorInterfacePanel2711-T10C8SERB

ALLEN BRADLEY X-355028 NSPP X355028

ABB DSAV-111 P/N.57350001-CN 61.2 Hz Video Board

ADI PMI OP227EY OP227EY T6223 IC chip good quality

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INDRAMAT TRANS-01.3 USPP TRANS013

XINIX 1011A-M USPP 1011AM

FANUC A16B-0160-0960 USPP A16B01600960

EMERSON 5A26391H18 USPP 5A26391H18

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OMRON C500-NC222-E NSFP C500NC222E

OMRON NT30C-ST141-E NSFP NT30CST141E

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Siemens 6ES5 441-8MA11 -- 6ES54418MA11

Siemens S5 6ES5 421-8MA11 6ES54218MA11

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Spectrum Controls 8000 RDI-132

Motorola Display Interface Module 2 M68DIM2 M68MM01-A2

WS-X4648-RJ45-E CATALYST 4500 E-SERIES 48-PORT 10/100/1000 RJ45

Siemens 6ES7 422-1BL00-0AB0 6ES7422-1BL00-0AB0

SIEMENS RWD82 Controller

Reliance 0-57552

Schneider Modicon John as Bo Duke in The Dukes of Hazzard 24X30 Poster

Schneider Modicon AS-B258-101 O TO 10V ANALOG MUX MERCURY RELAY

Schneider Modicon AS-P965-000 NSFP ASP965000

Schneider Modicon AS-B840

Schneider Modicon AS-B804-016

Modicon MM-PM10-300C PanelMate Plus 1000 MMPM10300C

SIEMENS SIMATIC 505-4032A INPUT MODULE 5054032A

SIEMENS 6ES5101-8RW11 24VDC PLC SIMATIC PROGAMM CONTROL

SIEMENS S5 6ES5 470-7LB12 ANALOG OUTPUT MODULE

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SIEMENS Simodrive 611 LT 160A 6SN1124-1AA00-0EA1

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Advantech PCA-6003 PCA-6003V

Allen-Bradley 1771-OBD/C DC Output Module 10-60VDC

ABB ACS800-04M-0320-3 VSD AC Drive

ADE 7000 system 14 station, 7200 system 9 station

6ES7614-1AH03-0AB3 Brand , Factory Sealed,

92-00273-09/09-00150 EATON MONITORS CRT REMANUFACTURED

SQUARE D RJA36120CU33A NSFP RJA36120CU33A

CONTROL TECHNIQUES TA-460 NSFP TA460

BOSCH RHO4.1/IPC300 USPP RHO41IPC300

NACHI RAX11 USPP RAX11

MEASUREX 51304754-150 NSFP 51304754150

FANUC A16B-1211-0092 USPP A16B12110092

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Siemens 6ES5-470-4UA12 USPP 6ES54704UA12

SIEMENS 6ES5-100-8MA01 USPP 6ES51008MA01

SIEMENS S5 ANALOG INPUT 6ES5 464-8MA21

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Schneider Modicon AS-B885-100 ASB885100 Motion Module

Schneider Modicon AS-516P-006 NSPP AS516P006

Schneider Modicon AS-M380-004 MEMORY CARTRIDGE ASM380004

Schneider Modicon AS-8533-003 USPP AS8533003

Schneider Modicon 100-367-1 Interface Card AS-S004-000 Rev A

Schneider Modicon AS-B875-002 ASB875002 Analog Input

SIEMENS U-25N INPUT MODULE NIB U25N

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SIEMENS SINUMERIK 820 6FC3261-1AC-Z BACKPLA5703749001.51 TESTED WARRANTY

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SIEMENS SIMODRIVE 6SN1145-1BA02-0CA1SINUMETIK 840D NCU-BOX 6FC52476FC53576S

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Advantech Motherboard PCA-6104 NIB

ALLEN-BRADLEY 2750-PA POWER SUPPLY

ABB 3HAB5957-1 16MB Memory Board DSQC 324

ACCURAY 086266-001 SYS SYSTEM SCANNER VME CONTROL BOARD CARD VMEBUS MODULE 85801

A1110616089 RG3-30T4

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ASEA BROWN BOVERI 57288531 NSPP 57288531

ALLEN BRADLEY 83003C1J1 USPP 83003C1J1

LOUIS ALLIS 46S1676-1010 USPP 46S16761010

HITACHI COMM-2H NSFP COMM2H

ALLEN BRADLEY 1336S-BRF100-AN-EN5 USPP 1336SBRF100ANEN5

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PWR-C45-4200ACV CATALYST 4500 4200W AC DUAL INPUT POWER SUPPLY 1YR - A

GSM Modem Pool 16 Ports RS232 PCI interface Wavecom Module AT Commands Q2403A

Tripp Lite B055001PS2 PS2 Server Interface Module B055-001-PS2

Siemens 6AG1312-5BE03-2AB0 CPU312C

Siemens IM153-1 6ES7153-1AA02-0XB0 6ES7 153-1AA02-0XB0

Modicon SW-AP9D-PDA

Schneider Modicon GOULD 884 CONTROLLER AS-884A-211

Schneider Modicon ASJ890101 RIO Processor AS-J890-101

Schneider Modicon AS-E380-904 NSFP ASE380904

Schneider Modicon AS-S908-012

Schneider Modicon AS-984A-001

Schneider Modicon Module Housing 7 Slot Rack AS-H819-209

Schneider TSX Quantum 140 DAO 853 00 140DAO85300 in Box Open Seal

Schneider Modicon AS-B809-016 NIB

POWER AUTOMATION PAMIO-2416 USPP PAMIO2416

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Great Condition MEDICAL ASSISTING PATIENT CARE & COMMUNICATION Module A

SIEMENS SIMODRIVE 6SN1146-1AB00-0BA2SINUMETIK 840D NCU-BOX 6FC52476FC5356 #2KH

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590A/0350/9/1/00 EUROTHERM DRIVES 115V 10A DC DRIVE

ABB VD86-SCAN VIDEO CONTROL BOARD IN A

A06B-0157-B075#7076 FANUC SERVO MOTORS

74LS51 IC 14 Pin Dip- Dual 2-Wide 2-IN AND/OR/Invert Gate

RELIANCE ELECTRIC 45C-225-D USPP 45C225D

ALLEN BRADLEY 1785-V30B NSFP 1785V30B

ALLEN BRADLEY 150-B54NBD NSPP 150B54NBD

GIDDINGS & LEWIS 1-21783 USPP 121783

TRIDIUM INC JACE-511-UI USPP JACE511UI

TELEMECANIQUE ATS-23C41N USPP ATS23C41N

FOXBORO P0400YE-0J USPP P0400YE0J

Siemens 6ES5-105-3RB41 USPP 6ES51053RB41

SIEMENS 6ES5 373-1AA81 6ES53731AA81

SIEMENS 6ES5-951-7LB13 USPP 6ES59517LB13

Siemens 6ES5 756-0AA11 USPP 6ES57560AA11

SIEMENS 6ES5 375-0LC21 6ES53750LC21

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

REMOTE I/O ADAPTER MODULE 1771-ASB B 1771 ASB B 5V CNC ALLEN BRADLEY A-B

Texas Instruments 305-01DA

Spirent Adtech 400361 AX/4000 Port Interface

VMware 1041M-T2B Server 4 Six-Core Istanbul 128Gb RAM

Siemens C98040-A7010-C1-3

Modicon AS-T984-105

Schneider Modicon AUTOMATION DEP 216N/AS-BDAP-216N

Schneider Modicon NIB AS-MBKT-085 ADAPTER CONNECTOR KIT 67

Schneider Modicon AS-BADU-205 REMAN ASBADU205

Schneider Modicon ASB807132 24VAC Input Module AS-B807-132

Schneider Modicon POWER SUPPLY AS-P120-000 OPEN BOX

Schneider Modicon AS-S901-100 I/O Processor Rev A14 AIND/UVG

SCHNEIDER 140-DI0-330-00/140-DIO-330-00 TSX QUANTUM DIGITAL OUTPUT MODULE XLNT

SHARP DC INPUT MODULE JW-212NA

Reliance 57405-E Drive Analog I/O Module 57405E

Siemens 6ES7 322-5GH00-0AB0 OUTPUT MODULE 16DO 24-48VU

SIEMENS SINUMERIK 6FX1122-1AC02 6FX11221AC02

NR&D NIOBRARA UNIVERSAL COMMUNICATION MODULE UCM4-D UCM4D

SIEMENS SIMODRIVE 611 6SN1118-0DK21-0AA0 NIB

SIEMENS SINUMERIK OP012 6FC5203-0AF02-0AAL Membrane Keypad

SIEMENS FURNAS ELECTRIC CO 8WH9-020-6FC10 NSFP 8WH90206FC10

ALLENBRADLEY1771OADOUTPUTMODULE16POINT120VAC

ALLEN BRADLEY SLC500 BASIC MODULE 1746-BAS C 1746BAS C

ABB PM633 3BSE008062R1, , PM6333BSE008062R1,

York Solid State Motor Starter SSS14L-46A

~ Allen Bradley 150-A97NA SMC-2 Smart Motor Controller 150A97NA AB 97A

MODICON AS-584M-220 USPP AS584M220

ALLEN BRADLEY 1395-B63-D1-P50 NSFP 1395B63D1P50

HALLIBURTON MP-48 USPP MP48

GE FANUC IC3600SPRB1 USPP IC3600SPRB1

SIEMENS 6SE6-440-2UC33-0FA1 USPP 6SE64402UC330FA1

SIEMENS 6AV4010-1AA10-0AA0 USPP 6AV40101AA100AA0

ALLEN BRADLEY 160-AA12NSF1P1 USPP 160AA12NSF1P1

Siemens 6ES5 923-3UC11 6ES59233UC11

Siemens S5 6ES5 955-3NF11 POWER SUPPLY UNIT PS955

SIEMENS 6ES5-482-8MA12 I/O MODULE DIGITAL 32 PT 24VDC

Siemens 6ES5 430-8MD11 USPP 6ES54308MD11

Siemens S5-100U input module 6ES5 433-8MA11

Siemens DCS Module 6DS1844-8FA in box, Seal opened,

SCHNEIDER TSXAEZ414 TSX MICRO PLC I/O MODULE 4ANALOG

Square D 8854-SL-10

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WE SHIP SAME CISCO WS-C3750G-12S-S CATALYST 3750G-12S SWICTH 1YR WARRANT