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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
　　針對本系統(tǒng)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(diào)節(jié)，為了提高系統(tǒng)操作性能，溫控表和變頻器與PLC進行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，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
　　根據(jù)現(xiàn)場設(shè)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(shè)計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進行通信。
　　2.4 確定通訊方案
　　(1)上位機以太網(wǎng)通信方案本工廠使用的上位機為亞控公司生產(chǎn)的組態(tài)王上位機組態(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雜，而且各動作也存在著邏輯關(guān)系，為了準確執(zhí)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(diào)試

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MITSUBISHI FR-A540-55K-NA-1 USPP FRA54055KNA1

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KEYENCE CORP LS-3060 USPP LS3060

GETTYS 110-223 USPP 110223

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NORTEL NETWORKS NT6D41AB NSPP NT6D41AB

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QY22 Mitsubishi PLC 16 Point Triac Output Card

General Electric IFM Interface Module w/ Cables Atari Commodore Series 1

Texas Instruments 6MT33 8 Input Output Interface Module

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Modicon PC-0984-480

Schneider Modicon OUTPUT MODULE RELAY AS-B814-108 SELECTABLE

Schneider Modicon AS-BDAU-252 Compact Analog Out ASBDAU252

Schneider Modicon AS-C484-264 USPP ASC484264

Schneider Modicon AS-J475-000

Schneider Modicon AS-BDAU-202 2 Channel In. Mod.

Schneider Modicon J200 REMOTE EXPANDER AS-J200-001 =

Schneider Telemecanique TWDPTO220DT TWDPT0220DT FreShip

Schneider 140DAI45300 48V Input Module 140-DAI-453-00

pulls AP763A Hp StorageWorks MDS 600 Dual I/O Module Option Kit 498472-001

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Indramat Interbus Communication Module RMK 12.2-IBS-BKL

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5370-CVIM2BC SERIES A, REV B, -------- 1

ABB Servo Drive DM0501, GNT2009357R0013 #10913

A06B-0148-B188#7008 FANUC SERVO MOTORS REMANUFACTURED

700HP 3PH 460V VFD TECO WESTINGHOUSE VARIABLE FREQUENCY DRIVE EQ7-4800-C

POWERTEC INDUSTRIAL MOTORS INC F213Y4A1N0A1000 USPP F213Y4A1N0A1000

ALLEN BRADLEY 1784-T50A USPP 1784T50A

ALLEN BRADLEY 1336T-MCB-SP33B USPP 1336TMCBSP33B

GENERAL ELECTRIC DS3800NEPA1C1B USPP DS3800NEPA1C1B

TEXAS INSTRUMENTS PLC 560-2820 NSPP 5602820

STROMAG CHA450.3CE USPP CHA4503CE

ELECTRO FLYTE 12M25-14-50 USPP 12M251450

Siemens 6ES5-090-8MA01 USPP 6ES50908MA01

SIEMENS 6ES5 305-7LA11 -- 6ES53057LA11

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ROBOTRON 503-1-0324-07 USPP 5031032407

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Wago 750-341 ETHERNET TCP/IP FIELDBUS COUPLER

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Modicon AS-S911-800

Schneider Modicon Automation TSX Compact Discrete Combi 8IN/8OUT DAP 220/AS-BDAP-220

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Schneider Modicon Motion Module M AS-B885-110 ~REPAIRED SUR~

Schneider Modicon AS-P120-000 COMPACT PC POWER SUPPLY NIB

Schneider Automation Inc 140 DAO 842 10 140DAO84210 Output Module

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