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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)�損壞設(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)備的操控與動力接線圖，并與什物相對照，以及時(shí)發(fā)現(xiàn)過錯并糾正。

　　(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，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：

　　①模仿辦法：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)，是否會發(fā)作邏輯誤動作。其缺陷是需求添加調(diào)試費(fèi)用和部分調(diào)試作業(yè)量。

　�、趶�(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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SM1000TPC QUICKMARQUEE CABLE TERMINAL PROGRAMMING

TRM-21006686 Connector for Target series digital I/O module J4 connector

20BD011A3AYNAND0 PowerFlex 700 AC Drive 20B

20G11BC1K4JN2NNNNN PowerFlex 755 AC Packaged Drive

22B-V5P0F104 PowerFlex 40 0.75 kW (1 Hp) AC Drive

140XBP00200 Quantum 背板, 2槽

284R-120P1K2-M05 120 Ohm Dynamic Brake Resistor

H5CR-L 100-240VAC,9.999s-9999h 一常開/閉?觸點(diǎn):5A

1492-SPM1D010-N MCB Supplementary Protector 1 A

通用型變頻器 6SE6 440-2UC27-5DA1 7.5 KW,275 x 520 x 245

電機(jī)啟動器 3VU13403MB00

150-C30NBR SMC-3 30A Smart Motor Controller

1609-D600E Uniterruptible Power Supply

1770-XYB PLC-5 Battery

193-EC1GG E3 42-210 A Overload Relay

195-GB01 Auxiliary Contact

2090-CPBM7E7-14AF04 MP-Series 4 m Length Pwr and Brake Cable

2093-PRS2 Kinetix 2000 2 Axis Slim Power Rail

CP9B-0WEB-0140-AZ Shielded motor power cable for B2is/B4is motors (straight connector). 14 meters

GFK-0074 Genius I/O PCIM User's Manual

IC200UEX210-24 Qty of 24, 28 point expansion. (16) 120VAC In, (12) 120VAC Out, 120/2 40VAC Power Supply (includes IC200CBL501)

IC647AHC001 PA Historian Connector

IC647PCMS25 Proficy Change Management Electronic Signature Option - 25 Concurrent Users

IC693CHS391NB Base, CPU, 10 Slots, Use With CPU35x, CPU36x and CPU37x. Base only. No battery included. Battery for CPUs ordered seperately.

IC754CKF15CTD Starter Kit/ 15 inch TFT Ctrl Fully Loaded/ 24VDC

KIT-GFS-344 Proficy ME LD-PLC Workshop Student Kit

SLC/1746 System D1746-6.5 HIGH SPEED COUNTER MODULE USER MANUAL

Distributed I/O 1732P-IB8M8 PROFIBUS 24VDC 8 INPUT W/M8

Application-specific products 1404-M805B-ENT-02 1404-M8 ETHERNET PM3000 CLASS 0.2

Operator Interface 2711-T10C15 PV1000 COLOR TOUCH, CNET & RS232 PRINT

Support 9301-2SE3400JPS SUPT RENEWAL CONTRACT FOR 93012SE3400JP

Support 9381-PA1KENR SUPT REINSTATEMENT CONTRACT FOR 9381PA1KEN

DeviceNet Products 1790-T8BV8VX LDX I/O, 24VDC, 8 UNIV IN/8 SINK OUT EXPN TERM BLK

RSI Software Products 9301-2SE3303 RSVIEW32 RUNTIME 1500 WITH RSLINX

RSI Software Products 9358-PBA10ENE RSBIZWARE BATCH FOR PROCESSLOGIX ARCHIVER 10 UNITS

Motion Control MPL-B540K-MJ24AA MOTOR,SERVO,19.4 NM,4000RPM,MULTI,460V,BRK,19.1KG

Motion Control 9101-1558 KIT,N-SERIES STRAIGHT ENCODER FDBK

GQPK3D200C2P QUICKPANEL 6" TFT COLOR GE LABEL

IC646MRE075 Logic PC & View (HRT) 75 Tag Runtime System

MTR-3T42-H-R-B-M-0 MTR-Series Servo Motor, Resolver, Metric, 24V Brake

SNAP 8C5 PC Port is 25-pin male and port on CNC is 25-pin male. This is for har dware handshake communications.

20BC072A0AYNANC1 PowerFlex 700 AC Drive 72 A 37 kW 20B

20F11NE6P1AA0NNNNN PowerFlex 753 AC Packaged Drive

22610-103-01-R FAN MR2B3 SPARE PART

140CPU67160 Quantum Unity Quantum 67160 CPU

281E-F12Z-10B-CR ArmorStart Direct Online RVSG Starter

C200H-AD001 模入單元,4路12位 A/D 4-20mA/1-5V/0-10V 可選

1492-RAIFM8S-3 Analog Interface Module

存儲卡 6ES7952-1AM00-0AA0 RAM/4M

變送器 3RS11201DD30

1497-F-BASX-0-N Control Circuit Transformer

1606-XL60DR Power Supply XL 60 W Power Supply

1762-L40BXB MicroLogix 1200 40 Point Controller

188-K3D010 Miniature Circuit Breaker 1 A

194L-HC4A-350 194L Control and Load Switch Actuator

2090-CPBM7DF-06AA07 MP-Series 7m Power and Brake Cable

2090-XXNPMF-10S12 Kinetix Drives 12m Standard Cable

BC647TDV935 "CIMPLICITY HMI Server 35,000 I/O Development and Runtime System with Proficy GlobalCare"

GC647PRTEE100 GlobalCare Complete - Proficy Portal Enterprise Edition Client Pack 100 User Ver 3.0

IC200MDL730 Output 24VDC POS LOGIC 2.0 amp per point(1 group o 8) with ESCP 8 points

IC646PCMSCH Proficy Change management Scheduler

IC647MQPU01 Machine Edition View for Quick Panel 1 user Upgrade from QuickDesigner with USB Hardware key

IC677ABO004 IP67 Analog Output Expansion Base, 4 channels. Configurable, per channelcurrent output ranges:0 mA to 20 mA, 4 mA to 20 mA;voltage output ranges:0 V to 10 V, +/-10 V, 0 V to 5 V, +/-5 V

IC697PWR724 Power Supply, 24 Vdc, 90 Watts