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在企業(yè)搬遷工作中，原來在包裝崗位有兩臺其他品牌的小型 PLC在使用，分別控制堆垛崗位和封切熱縮崗位。目前該型號產(chǎn)品已經(jīng)被淘汰，而在搬遷后發(fā)現(xiàn)，PLC上電無反應(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，PLC通過網(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)場設(shè)備匯總需要輸入點(diǎn)13個，輸出點(diǎn)12個，使用 S7-200 SMART系列的SR40型號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臺安川V1000變頻器和2臺山武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)過查找發(fā)現(xiàn)組態(tài)王已經(jīng)更新了S7-200 SMART的驅(qū)動，驅(qū)動名稱：S7 TCP.DLL，驅(qū)動版本：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作最為復(fù)雜，而且各動作也存在著邏輯關(guān)系，為了準(zhǔn)確執(zhí)行各封切動作，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

Schneider Modicon AS-B805-016 INPUT MODULE 16POINT 115VAC

Schneider Modicon ASB824016 REMAN AS-B824-016

Schneider Modicon AS-B279-501

Schneider Modicon AS-E480-904

Schneider Modicon AS-J878-000 MODEM MODULE ASJ878000

Schneider Telemecanique XBTF034510

SIEMENS Input Module 6ES5 421-8MA12

SIEMENS / TI 505-4616 DISCRETE OUTPUT MODULE

Siemens Operator Panel OP 17-DP12 6AV3 617-1JC30-0AX1

SIEMENS SINUMERIK 3 CU/EU COUPLER 6FX1120-3BB01

TELEMECANIQUE TSX-MAP-1074 COMMUNICATION MODULE TSXMAP1074

SIEMENS 6SN1118-0DM21-0AA0 USPP 6SN11180DM210AA0

SIEMENS Simodrive (Bima Axis Card) 6SN1122-OBA11-OAA1 inBox

SIEMENS 6FC53570BA330AE0

Advantech PCM-7130 Rev.A1 NIB

Allen-Bradley 1746-OV16 SLC500 Output Module Series B

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 84824

ADEPT TECH 10330-00710 USPP 1033000710

(00 no lot#) ITE Circuit Breaker HNXD63B120 1200A 600V

IMPERIAL 08124800 USPP 08124800

TECH MOTIVE TOOL C4100AP1V116051 USPP C4100AP1V116051

DOMINO 37711 NSFP 37711

CTRL SYSTEMS INC 000031 NSFP 000031

PE FIBEROPTICS CD300 USPP CD300

MODICON AS-516P-006 NSFP AS516P006

HIRSCHMANN MS20-1600SAAEHH03.0 NSFP MS201600SAAEHH03

Siemens 6ES5 308-3UC11 6ES53083UC11

Siemens 6ES5-525-3UA21 USPP 6ES55253UA21

SIEMENS 6ES5-373-0AA41 NSFP 6ES53730AA41

Siemens 6ES5 243-1AA12 Analog Module

Siemens 6ES5-421-8MA12 6ES5421MA12 F299

Siemens 6GK7243-2AX01-0XA0 6GK72432AX010XA0

Siemens TP178 6AV6 640-0DA11-0AX0 Touchscreen Glass

Siemens 6ES5762-1AA12

Larscom DIM-111 DTE Interface Module Serial Adapter

YASKAWA ELECTRIC JAMSC-120NOM27100 USPP JAMSC120NOM27100

SIEMENS 6ES7 223-1BF21-0XA0 6ES7223-1BF21-0XA0 FreeShip

Siemens OP37 6AV3 637-1ML00-0BX0 Membrane Keypad

Red Lion SERIES 600 (66140)

Schneider Modicon AS-B807-132 ASB807132 32 Point 120VAC Input NIB

Schneider Modicon AS-884A-201 PROCESSOR 3.5K W/REMOTE I/O MODULE

Schneider Modicon AS-P120-250 USPP ASP120250

Schneider Modicon AS-B239-001 ASB239001 High Speed Counter NIB

Schneider Modicon AS-5378-002 BATTERY BACK UP GOOD TAKEOUT

Modicon TSX Quantum 24-230 VAC Output Module 140DAO84000

SIEMENS SIMATIC S7 SM323 I/O INPUT OUTPUT MODULE PLC 6SE7 323 6ES7323-1BL00-0AA0

Telemecanique XBTF032110 demo only

SIEMENS SIMATIC RELAY OUTPUT MODULE 6ES7 322-1HH01-0AA0 E-STAND:03 NIB

Siemens 9510 9510EC-1156-GZTA NIB Power Meter Display ION Ethernet Access

SIEMENS Sinumerik I/0 Card Type 03400 GE 548 184 9001

SIEMENS 6SN1123-1AA00-0BA1 6SN11231AA000BA1 Drive

SIEMENS Simodrive 6SN1123-1AA01-0F01 LT-MODUL INT.200A Version C Free S&H

SIEMENS HMI 6FC5253-6BX10-2AFC PCU 50 566mHZ6FC5210- 00F20-0AA0840D BS003

Advantech PCM-5825

ALLEN-BRADLEY 2711-K5A20 PANELVIEW 550 2711K5A20 CLEAN TESTED GOOD COND.

ABB 5SDF0545F0001 3BHL000395P0001 ICGT Module 68mm Thyristor ACS1000

ACS800-U1-0040-5 ABB INDUSTRIAL DRIVE (480 volt, 40 HP)

68BM330LBX22 SANYO DENKI SERVO MOTORS REMANUFACTURED

8520-AA6 ALLEN BRADLEY DRIVES REMANUFACTURED

SIEMENS 6SE3-214-0DA40 NSPP 6SE32140DA40

AVTRON ADD-32 USPP ADD32

ASEA BROWN BOVERI EH800-C1 USPP EH800C1

MODICON 140-AII-330-00C NSFP 140AII33000C

INDRAMAT MDD071C-N-030-N2L-095GA0 USPP MDD071CN030N2L09

ASEA BROWN BOVERI 57310001-S USPP 57310001S

TEXAS INSTRUMENTS PLC 7MT-1504 NSPP 7MT1504

Siemens 6ES5-441-7LA12 NSFP 6ES54417LA12

SIEMENS 6ES5 521-8MA21 -- 6ES55218MA21

SIEMENS S5 6es5 308-3ub11 profibus

Siemens S5 6ES5 491-0LB11 ADAPTER CASING

Siemens 6ES7 952-0KF00-0AA0 6ES79520KF000AA0

Siemens S5 PLC Cable PC-TTY 6ES5 734-1BD20 NIB FS

POWER AUTOMATION PAMIO-2416 USPP PAMIO2416

Honeywell Ademco 4100SM Serial Interface Module

Wago 289-457 Interface Module 25-Pin Female D-Sub WARRANTY

Siemens 6DS1312-8BB

Siemens LOGO! 230RC 6ED1 052-1FB00-0BA6 NIB

Omron 3G2A5-OD213

Schneider Modicon AS-P120-000 AC Power Converter 115/230VAC

Schneider Modicon LEVEL-3 16K 3CARD CHASSIS 584 AS-584A-351

Schneider Modicon AS-H819-103 NSFP ASH819103

Schneider Modicon Gould/ AS-H827-209

Schneider Modicon AS-BDAU-202 ANALOG OUTPUT MODULE ASBDAU202

Schneider Modicon RELAY MODULE AS-B266-501 ~

TELEMECANIQUE HMI XBT-N400 in Box

SCHNEIDER TELEMECANIQUE OTB1E0DM9LP ETHERNET INTERFACE MODULE

SIEMENS/TI/CTI 505-6208 8CH ANALOG OUTPUT MODULE XLNT

Siemens 6AV6 545-0BA15-2AX0 6AV65450BA152AX0 Panel

SIEMENS Sinumerik 6FC5111-0CA73-0AA1 Terminal Block

GE FANUC COMMUNICATION MODULE IC693CMM301 IC693CMM301M Free Ship

SIEMENS SIMODRIVE 6SN1145-1AA01-0AA1SINUMETIK 840D NCU-BOX 6FC5247-0AA00- #7

SIEMENS SINUMERIC 840D 6FC5357-0BB23-0AE0

SIEMENS HP LPQ 1000 Printer Ribbon HP C3207A - HP LPQ1000

Allen-Bradley Color PanelView Plus 1000 Operator Interface

AB PANELVIEW PLUS 1250, #2711P-RN6, SER-B, 30 ,

AC Motor Invertor - 50 HP - 600 Volt - Three Phase Input

A06B-0614-B031#0100 FANUC DC SERVO MOTORS REMANUFACTURED

750' wake forest 4/0 4/0 4/0 2/0 Cable Wire Direct Burial XLP USE URD 600 Volt

RELIANCE ELECTRIC S-6R9009 USPP S6R9009

ALLEN BRADLEY 5250-LP4 NSFP 5250LP4

ALLEN BRADLEY 20AD027A3AYNANNN USPP 20AD027A3AYNANNN

INDRAMAT MAC071C-0-NS-3-C/095-A-0/S001 USPP MAC071C0NS3C095B

YASKAWA ELECTRIC CIMR-G5M50301F NSFP CIMRG5M50301F

WESTINGHOUSE 293B414A11 USPP 293B414A11

INDUSTRIAL DEVICES NH-105A-24-MF1-MT1-DB-032 USPP NH105A24MF1MT1DB

Siemens 6ES5246-4UA31 6ES5 246-4UA31 SIMATIC S5 IP246I Positioning Module

SIEMENS 6ES5 377-0AA11 6ES53770AA11

SIEMENS Interface Module Coupler 6ES5 312-5CA21 V2 Appears to be

Siemens ANALOG INPUT MODULE PLC CARDS5 6ES5 464-8MF11 6ES5464-8MF11

SIEMENS 6ES7 133-1BL01-0XB0 6ES7133-1BL01-0XB0 ET200L

Siemens MTT95A12N 95A/1200V THYodul MTT 9 A 12 N

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

Texas Instruments 505-4608

Subaru Outback Legacy Factory OEM USB Media Interface Module H621SAJ210

UBR7200-NPE-G1 CISCO UBR NPEG1 ENGINE W/ 512MB D/64MB F 3 GE/FE/E

Siemens COROS OP15 6AV3515-1EB30 ping Worldwide

Modicon D4-043506657

Schneider Modicon #NAME

Schneider Modicon 91-01254-00

Schneider Modicon AS-BDEP-210 NSFP ASBDEP210

Schneider Modicon ASBDAP216N A120 IO DC OUT 16 pt AS-BDAP-216N

Schneider Modicon -AS-506P-F12

Schneider Modicon DAP-220/AS-BDAP-220 Discrete Combination ASBDAP220 NIB

Schneider Soft Starter ATS48D38Q 18.5KW

SCHNEIDER MODICON TSX PREMIUM SINK CONNECTION INPUT MODULE TSXDEY64D2K

Quantum 8pt Thermoc Input Module model 140 ATI 030 00

Siemens 6ES54547LB11 6ES5-454-7LB11 Output Module 24VDC 2.0A in Sealed Box

SIEMENS OFFER & WIN 6FX1111-5AA00 Sinumerik Rack

MITSUBISHI A1SJ71UC24-R4 COMMUNICATION MODULE GOOD TAKEOUT

SIEMENS SIMODRIVE 6SN1123-1AA00-0DA1 / 6SN1118-0DM33-0AA0

SIEMENS SINUMERIK CHASSIS 810 M GA2 6FC3541-OAC-Z DC24 USMT CNC MILL MACHINE

SIEMENS /MOORE 61H F/R RELAY BOOSTER NNB

Allen-Bradley Versaview 6189-RDT10C

Allen Bradley SLC 500 1746-OA8 SER D Output Module

ABB ROBOTIC DRIVE 3HAB8101-6/11A

A06B-0147-B075#7008 FANUC SERVO MOTORS REMANUFACTURED

0200-36686 Ring single Low profile 200mm JMF CER

NACHI AUXL-111C-A0 USPP AUXL111CA0

ALLEN BRADLEY 1756-L55M14 NSFP 1756L55M14

ALLEN BRADLEY 1336-BDB-SP19D USPP 1336BDBSP19D

GENERAL ELECTRIC 531X152IOCAKG1 NSFP 531X152IOCAKG1

SQUARE D TVS-2EMA24AIC NSFP TVS2EMA24AIC

SIEMENS 6SE7-028-6EC85-0AA0 USPP 6SE70286EC850AA0

BALLUFF BIS-C-602-019-652-03-KL2 USPP BISC60201965203K

Siemens 6ES5 945-7UA11 6ES59457UA11

Siemens Simatic S5 6ES5 943-7UB21 6ES59437UB21 115U CPU

SIEMENS 6ES5-705-0BB20 USPP 6ES57050BB20

Siemens 6ES5 490-7LA11 USPP 6ES54907LA11

Siemens 6AV3627-1QL01-0AX0 LCD Display

Siemens Inverter Card 6SE7 090-0XX84-0FJ0

Same as model AVS-OP-0404-DD0 part FGP46-0404-DD0 video

TB Woods DST150V4B3G

SIEMENS INTERFACE MODULE 6ES5312-5CA21

Color/Touch Screen/EtherNet Terminal

Siemens 6SE7033-2EG84-1JF0

SIMENS MP277-10 6AV6 643-0CD01-1AX1 Protective Film

Schneider Modicon AS-BDAP-210 TSX OUTPUT MODULE NIB

Schneider Modicon ASB872200 EXCELLENT Analog OUT Module AS-B872-200

Schneider Modicon AS-B855-016 USPP ASB855016

Schneider Modicon AS-B875-002 ASB875002 Free Ship

Schneider Modicon BUS EXTENSION CABLE BXT 201/ AS-WBXT-201

Schneider Modicon AS-H827-209 Primary Rack 11Slot

Schneider Modicon PanelMate Plus 1000 MM-PM1030SC 92-01686-00

SIEMENS 6ES5 464-8MF21 ANALOG INPUT MODULE

RME HAMMERFALL HDSP AES-32- PROAUDIOSTAR

Siemens Apogee MBC Module PTM6.2Q250-M Digital Output Module

SIEMENS Sinumerik DMP Module Modul 6FC5111-0CA01-0AA0

RELIANCE ELECTRIC 57416-S REMOTE I/O COMMUNICATIONS MODULE 57C416

SIEMENS CONTROLLER CARD 6SN1118-1NH00-0AA2

SIEMENS XVGA box replace monitor to LCD 6FC4600-0AR50 6FC5103-0AB01 SC-1200

SIEMENS 6FC5-110-0BA01-1AA0 NSFP 6FC51100BA011AA0

AllenBradley2711-K9C9PanelView900OperatorInterfaceSeriesCRev.L

ALLEN BRADLEY VersaView 1200P TOUCH SCREEN OPERATOR INTERFACE 6181P-12TSXPH

ABB INTERRUPTER ASSEMBLY 539D19302 FOR 345KV CIRCUIT BREAKER

Advanced Energy Mercury 10013 Match, P/N 27-256558-00

(no #) Cervis Remote Control Unit TM70/1.13 With Cable

MEASUREX 08591501 USPP 08591501

ALLEN BRADLEY 1336E-B040-AE-EN USPP 1336EB040AEEN

GE FANUC IC697CSE784 USPP IC697CSE784

FANUC A16B-1210-0030 NSPP A16B12100030

SIEMENS 6AV7-802-0BA02-1AC0 NSFP 6AV78020BA021AC0

RELIANCE ELECTRIC 419437-D USPP 419437D

SIEMENS 6FC5-110-0DB03-0AA2 USPP 6FC51100DB030AA2

Siemens 6ES5 470-4UC13 6ES54704UC13

Siemens 6ES5-947-3UR21 USPP 6ES59473UR21

SIEMENS 6ES5-440-8MA21/6ES5440-8MA21 OUTPUT MODULE NIB

Siemens 6ES5 923-3UC11 COORDINATOR MODULE NIBBNO

Siemens S5 6ES5-318-8MB13

Siemens C98043-A1203-L23-06

Siemens 6ES5 470-4UC13 -FS- 6ES54704UC13

Square D 8030 CC-15

Omron C500-II002 Expansion Rack Interface Module

WS-C3550-12T CISCO SWITCH 10-10/100/1000 PORTS 2 GBIC PORTS: EMI

Siemens 6ES7316-2AG00-0AB0

Siemens Simovert 6SE7016-1TA61

Remote Display RD-300

Schneider Modicon AS-P120-125 SEALED 125VDC Supply ASP120125

Schneider Modicon AS-B548-000 USPP ASB548000

Schneider Modicon AS-W600-006 NSPP ASW600006

Schneider Modicon AS-BDEP-216 16 Point Input Module

Schneider Modicon AS-B826-032/ASB826032 Output Module OFFERS ACCEPTED

MODICON ANALOG OUTPUT MODULE AS-B872-100

SIEMENS EM221 DI 8XDC24V 6ES7 221-1BF00-0XA0 Digital Input Module

Sharp JW-31LM I/O MODULE 32-SLAVE STATIONS 345.6KB 504 POINTS

Siemens Operator Interface 6SE32900XX878BF0 23884

SIEMENS Sinumerik 6FC3251-1AC-Z 810T Controller

SUPPLYNET COMMUNICATIONS TANKLINK 3810 DIGITAL CONTROL CONTROLLER MODULE LLC

SIEMENS 6SN1118-1NH01-0AA1 6SN11181NH010AA1

SIEMENS Lt-Modul INT. 50A Simodrive 6SN1123-1AA00-0CA0

SIEMENS 6FC5248-0AF20-2AA0 MOUNTING BRACKET

Advantech Remote Data Acquisition Module ADAM-4013 NIB

ALLEN-BRADLEY 1746-0A16 SLC500 SERIES D OUTPUT MODULE

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 88205

ADEPT TECH 10332-00714 USPP 1033200714

(1) 4 Fanuc Motors and (1) Mitubishi Motor

INDRAMAT DDC01.2-N200A-DA02-01-FW USPP DDC012N200ADA020

TELEMECANIQUE LA9-B102 NSFP LA9B102

ELDEC 5250062 USPP 5250062

CUTLER HAMMER A13GN0 USPP A13GN0

PRATT & WHITNEY DU205E USPP DU205E

MODICON AS-B260-001 USPP ASB260001

INDRAMAT IKG0022-22 NSPP IKG002222

Siemens 6ES5 314-3UA11 6ES53143UA11 Free Ship

Siemens 6ES5-530-7LA12 NSFP 6ES55307LA12