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在企業搬遷工作中，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。目前該型號產品已經被淘汰，而在搬遷后發現，PLC上電無反應，必須要進行更新換代。
　　1　工藝原理
　　本包裝設備，完成對本廠建材產品的包裝，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：對塑料膜進行切斷和封口;③熱縮：使PE膜加熱收縮包裹產品。
　　2　方案選型
　　2.1 控制方案設計
　　針對本系統的特點，適合采用集成了IO點的小型PLC。而溫度可以單獨交給溫控表進行控制，速度由變頻器進行調節，為了提高系統操作性能，溫控表和變頻器與PLC進行MODBUS通信，交換數據。同時，PLC通過網線連接至中控室上位機，完成數據采集、顯示和必要的操作。
　　2.2 PLC選型及IO表設計
　　根據現場設備匯總需要輸入點13個，輸出點12個，使用 S7-200 SMART系列的SR40型號CPU并設計IO表。
　　2.3 其它主要電氣設備選型
　　另外選擇了1臺安川V1000變頻器和2臺山武SDC36溫控表分別進行速度和溫度的控制，它們都支持通過MODBUS通信協議與 S7-200 SMART進行通信。
　　2.4 確定通訊方案
　　(1)上位機以太網通信方案本工廠使用的上位機為亞控公司生產的組態王上位機組態軟件，經過查找發現組態王已經更新了S7-200 SMART的驅動，驅動名稱：S7 TCP.DLL，驅動版本：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構，能夠方便地接入系統。
　其中讀取和寫入的功能碼分別是03H和10H。
　　3　編程與調試
　　3.1 IO控制程序編程與調試
　　塑封膜包裝線中堆垛和封切工序的動作最為復雜，而且各動作也存在著邏輯關系，為了準確執行各封切動作，采用步進控制。其他的只采用普通的邏輯控制即可。
　　3.2 MODBUS通信程序編程與調試

Schneider Modicon AS-C484-164 USPP ASC484164

Schneider Modicon AS-B875-111

Schneider Modicon AS-S911-000 HOT STAND BY MODULE GOOD TAKEOUT

Schneider Modicon / Communication Processor Module AS-C921-101

MODICON PLC MODULE AS-B838-032 24 VDC OUTPUT

Siemens 6ES7131-4BD00-0AA0 Digital Input Module Simatic S7 24vdc3

Schneider Telemecanique Contactor LC1D09 M7C

Siemens6ES7222-1EF00-0XA0EM222OutputModule

Siemens 6AV6542-0BB15-2AX0 6AV6 542-0BB15-2AX0 SIMATIC OP170B 5.7 Keypad Panel

SIEMENS SINUMERIK 6FC 3671-0FB-Z CONTROL RACK

GE FANUC IC600CB516M COMMUNICATION MODULE

SIEMENS SINUMERIK 6FC3538-3EF 6FC35383EF USED

SIEMENS MOORE CO. MODEL 63BD-L DIFFERENTIAL TYPE FLOW CONTROL

ALLENBRADLEY FLEX I/O ANALOG OUTPUT MODULE CAT:1794-OF4I

A-B Allen Bradley 8510A-A11-A2 AC Spindle Drive Controller 200/230V

AC Motor Control Drive - 50 HP - 600 Volt - Three Phase Input

A06B-0502-B756 FANUC AC SERVO SPINDLE REMANUFACTURED

75 KW 575v Electric Generator WEG Model: GTA200 MI 30 Bi Lateral Rotation

RELIANCE ELECTRIC 86466-59SCR USPP 8646659S

ALLEN BRADLEY 4100-234-RL USPP 4100234RL

ALLEN BRADLEY 1785-L20E USPP 1785L20E

INDRAMAT DDC01.2-N200A-DS01-02 USPP DDC012N200ADS010

YAMATAKE 82408667-001 USPP 82408667001

VIBRO METER VM600-CSA USPP VM600CSA

HONEYWELL 30732219-002 USPP 30732219002

Siemens 6ES5-243-1AA1/6ES5243-1AA1 ANALOG INPUT MODULE XLNT

SIEMENS 6ES5 376-0AA11 6ES53760AA11

SIEMENS Digital Output Module 6ES5 456-4UA12 Version 1 Possibly

Siemens 6ES5 998-8MA22 NSFP 6ES59988MA22

Siemens 6ES5921-3UA12

Siemens MP277-10 6AV6643-0DD01-1AX1 Touch Glass

RELIANCE ELECTRIC 0-57405-C USPP 057405C

Texas Instruments 500-5828A

SQUARE D S48891 MOD DIFF GROUND FAULT INTERFACE MODULE

UNIPRO 24002156 USPP 24002156

Siemens CB24 COM BOARD 6RX1240-0AK01

Modicon AS-W904-050

Schneider Modicon 3038DEP216/AS-BDEP-216 Input Module

Schneider Modicon S911 PROCESSOR MODULE AS-S911-801

Schneider Modicon AS-BDAU-202 2 Point Output Module

Schneider Modicon AS-BDAP-204 Compact Out Module ASBDAP204

Schneider Modicon /Schneider AS-B873-011/AB873011 NICE

Schneider Modicon Compact AS-BDAP-216 ASBDAP216 DC Output NIB

Schneider Modicon TSXPCX1031-C TSXPCX1031C PLC Cable

SCHNEIDER TSX COMPACT DISCRETE INPUT FAST INPUT MODULES DEP 220/AS-BDEP-220

RADISYS EXM18-RS422 USPP EXM18RS422

SIEMENS 6ES5-456-7LA11/6ES5456-7LA11 OUTPUT MODULE NIB

SIEMENS SINUMERIK OP010 6FC5203-0AF01-0AA0 MembraKeypad

Mitsubishi F2-20GF Communication Module Free Ship

SIEMENS Simodrive 6SN1118-0DG22-0AA0 E GWE-567008901365

SIEMENS Sinumerik FM 6FC5210-0DA00-1AA1 6FC5 210

SIEMENS 6FC5203-0AB00-0AA0 Sinumerik OP030 Free Ship

ALLENBRADLEY1734-0B8STANDARDSOURCEOUTPUTMODULE8CHANNEL24VDC1A/24VA

Allen Bradley SLC 500 1747-L20A Series B Processor with 2 Output Modules

ABB ROBOT TRALLFA TEACH PENDANT 3E031712 TESTED &

A06B-0143-B175#7008 FANUC SERVO MOTORS REMANUFACTURED

00415 GE IC640MWS902A Demo Unit

MOORE PRODUCTS 39ACM28ADN USPP 39ACM28ADN

ALLEN BRADLEY 150B97NBD8L NSPP 150B97NBD8L

ALLEN BRADLEY 1326AS-B440G-21-K4 USPP 1326ASB440G21K4

GENERAL ELECTRIC 36C774505ABG01 USPP 36C774505ABG01

SQUARE D KCL341252361 NSFP KCL341252361

SIEMENS 6SC-9811-4BF54 USPP 6SC98114BF54

ASEA BROWN BOVERI APSAF-03 USPP APSAF03

Siemens 6ES5 943-7UB21 6ES59437UB21

Siemens Simatic S5 6ES5 465-4UA11 6ES54654UA11 Analog

SIEMENS 6ES5-700-3LA12 USPP 6ES57003LA12

Siemens 6ES5 460-4UA12/6ES54604UA12 Analog Input

Siemens 6AG1 223-1PL22-2XB0 6AG1223-1PL22-2XB0 FreeShip

Siemens IGBT BSM75GB120DN1E3204

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

Square D SERIPIEX SET-UP TOOL

SIEMENS INTEL HTRI-D DUAL INTERFACE MODULE BRAND NEFREE SAME DAY USA

SERIES C F/W REV A PKG 06/09/2009

Siemens 6SE7022-6EC61

Siemens TXB1.P1

Schneider Modicon Compact AS-PRTU-252 ASPRTU252 NIB

Schneider Modicon ASB883200AS-B883-200 Thermocouple Input Module

Schneider Modicon AS-B838-032 Discrete Output Module

Schneider Modicon AS-BDEP-218 DISCRETE INPUT MODULE FS

Schneider Modicon B807 AS-B807-132 INPUT MODULE 800I/O 115VAC 32PT PLC PROGRAMMABLE L

Schneider Modicon AS-H827-100 Secondary Rack

Schneider Output Module QUANTUM 140 DDO 353 00 2759

Siemens 6ES5421-8MA12 Digital Input Module 7309

ROBOTRON 503-1-0324-19 USPP 5031032419

Siemens Contactor 3RT1033-3AK60 110V 50Hz 120V 60Hz

SIEMENS Sinumerik 850T Control #7103SO

RELIANCE ELECTRIC DIGITAL CONTROL SYSTEM NETWORK COMMUNICATIONS MODULE 57404-1D

SIEMENS CONTROLLER CARD 6SN1118-0BK11-0AA0

SIEMENS Simodrive 6SN1123-1AA00-0CA1

SIEMENS 6FC5110-0CB01-0AA0 6FC51100CB010AA0 version F

AllenBradley2711P-RP6A

ALLEN BRADLEY VERSAVIEW 1500M OPERATOR INTERFACE TOUCH PANEL 6186-M15AL SER B

ABB G04200A00 AC DRIVE 25HP 460VAC 42AMP XLNT

Advanced Energy Corp. 5KW DC Power Supply

(M6-2) 1 RTA PAVIA SBC-04B DRIVE M6-2

MARPOSS 3708630010 NSPP 3708630010

ALLEN BRADLEY 1336-B015-EOE-L3 USPP 1336B015EOEL3

GE FANUC IC3600STKK1 NSFP IC3600STKK1

FANUC A06B-6064-C303 USPP A06B6064C303

SIEMENS 1PP7113-4AA91-ZT00 NSPP 1PP71134AA91ZT00

RELIANCE ELECTRIC 0-846181-3R USPP 08461813R

SIEMENS 6ES5-242-1AA41 USPP 6ES52421AA41

Siemens 6ES5 467-8EF11 6ES54678EF11

Siemens 6ES5-944-7UA22 USPP 6ES59447UA22

SIEMENS 6ES5-435-7LA11 USPP 6ES54357LA11

Siemens 6ES5 701 1LA12 EXPANSION RACK I/O ER1

Siemens S5 6ES5 928-3UB11 6ES59283UB11

Siemens C79453-A3033-A581

SIEMENS 6ES5-305-7LA11 USPP 6ES53057LA11

Square D 8020 SCP-323

OEM Mercedes Benz HMI Bluetooth Module Cradle Adapter Interface B6 787 5878

WS-C3750G-16TD-S FREE 1 YEAR - CATALYST 3750G SWITCH

Siemens 6ES7253-1AA22-0XA0

SIEMENS SIMATIC PG702 6ES7702-0AA00-0YA0 PG 702 in Box ping

Reliance 803456-21T

Schneider Modicon ASWBXT201Compact Primary Rack AS-WBXT-201

Schneider Modicon AS-B375-000 USPP ASB375000

Schneider Modicon AS-T884-001 USPP AST884001

Schneider Modicon AS-BDAP-212 ELECTRONIC

Schneider Modicon AS-B824-016

MODICON AS-B352-001 OUTPUT MODULE OLD STOCK FREE SAME DAY SHIPPING USA

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 6ES53083UB11 IM308B

Siemens S5 6ES5 490-7LB21 Front Connector

Siemens 6ES7 645-1DK40-0AE0 6ES7 645-1DK40-0AE0 ping Worldwide

Siemens S5 PLC Cable 6ES5712-8AF00 6ES5 712-8AF00

POWER PROCESS 512-K8705 TEMPERATURE CONTROLLER 2OUT 2AL

Honeywell Ademco 4100SM Serial Interface Module

WAGO 289-447 INTERFACE MODULE WITH SUB MINI D-MALE CONN. 25 POLE 289447

Siemens 6DS1312-8AB in box, seal opened,

Siemens LOGO! 230RC 6ED1 052-1FB00-0BA5 in Box, Seal Intact,

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