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　PLC控制系統(tǒng)的設備與調(diào)試，觸及到各項作業(yè)，而且只能按序進行，一環(huán)緊扣一環(huán)，稍有不小心都將導致調(diào)試失利，不但延誤工期，甚至會損壞設備。本文介紹了在現(xiàn)場實踐中總結(jié)出的PLC控制系統(tǒng)的設備與調(diào)試技能經(jīng)驗，并對現(xiàn)場經(jīng)常出現(xiàn)的設備、調(diào)試相關問題，提出評論定見和解決計劃。

　　一、體系的設備與調(diào)試

　　合理安排體系設備與調(diào)試程序，是確保高效優(yōu)質(zhì)地完成設備與調(diào)試任務的要害。

　　1、前期技能準備

　　體系設備調(diào)試前的技能準備作業(yè)越充沛，設備與調(diào)試就會越順暢。前期技能準備作業(yè)包含下列內(nèi)容：

　　(1)熟悉PC隨機技能材料、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)設備的操控要求要有全面的了解，在此基礎上，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，是前期技能準備的重要環(huán)節(jié)。

　　(3)熟悉各工藝設備的功用、規(guī)劃與設備狀況，特別是各設備的操控與動力接線圖，并與什物相對照，以及時發(fā)現(xiàn)過錯并糾正。

　　(4)在全面了解規(guī)劃計劃與PC技能材料的基礎上，列出PC輸入輸出點號表(包含內(nèi)部線圈一覽表，I/O所在位置，對應設備及各I/O點功用)。

　　(5)研讀規(guī)劃提供的程序，對邏輯雜亂的部分輸入、輸出點制造時序圖，一些規(guī)劃中的邏輯過錯，在制造時序圖時即可發(fā)現(xiàn)。

　　(6)分子體系編制調(diào)試計劃，然后在團體評論的基礎上綜合成為全體系調(diào)試計劃。

　　2、PLC商檢

　　商檢應有甲乙兩頭共同進行，應承認設備及備品、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驗室及現(xiàn)場調(diào)試時驗證。商檢成果，兩頭應簽署交換清單。

　　3、實驗室調(diào)試

　　(1)PLC的實驗室設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，按設備提要以同軸電纜將各站與主機、編程器、打印機等相銜接，查看接線正確，供電電源等級與PLC電壓選擇相契合后，按開機程序送電，裝入體系配置帶，承認體系配置，裝入編程器裝載帶、編程帶等，按操作規(guī)程將體系注冊，此刻即可進行各項操作實驗。

　　(2)鍵入作業(yè)程序

　　(3)模仿I/O輸入、輸出，查看修正程序本進程的意圖在于驗證輸入的作業(yè)程序的正確性，該程序的邏輯所表達的工藝設備的聯(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程，闡明程序有誤，應進行修正。在這一進程中，對程序的了解將逐漸加深，為現(xiàn)場調(diào)試作好了準備，同時也可以發(fā)現(xiàn)程序不合理和不完善的部分，以便進一步優(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，以鈕子開關模仿輸入節(jié)點，以小型繼電器模仿生產(chǎn)工藝設備的繼電器與接觸器，其輔佐接點模仿設備工作時的回來信號節(jié)點。其長處是具有模仿的真實性，可以反映出開關速度差異很大的現(xiàn)場機械觸點和PLC內(nèi)的電子觸點相互銜接時，是否會發(fā)作邏輯誤動作。其缺陷是需求添加調(diào)試費用和部分調(diào)試作業(yè)量。

　　②強置辦法：使用PLC強置功用，對程序中觸及現(xiàn)場的機械觸點(開關)，以強置的辦法使其“通”、“斷”，迫使程序工作。其長處是調(diào)試作業(yè)量小，簡便，不需另外添加費用。缺陷是邏輯驗證不全面，人工強置模仿現(xiàn)場節(jié)點“通”、“斷”，會構(gòu)成程序工作不能連續(xù)，只能分段進行。

　　依據(jù)我們現(xiàn)場調(diào)試的經(jīng)驗，對部分重要的現(xiàn)場節(jié)點采納模仿辦法，其他的選用強置辦法，取二者之長互補。邏輯驗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、時刻、調(diào)試內(nèi)容、修正記載、毛病及處理、交代驗收簽字，以樹立調(diào)試作業(yè)責任制，留下調(diào)試的第一手材料。關于規(guī)劃程序的修正部分，應在規(guī)劃圖上注明，及時征求規(guī)劃者的定見，力求準確表現(xiàn)規(guī)劃要求。
 

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IC200UDR002-24 Qty of 24, 14 point PLC, (8) 24VDC In, (6) Relay Out, 24 VDC Power Supply

IC752CBT010RR Datapanel 320T ME (Mono Expansion): 320x240 1/4 VGA Monochrome LCD with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock. With 2M memory and PC/104 capability.

MTR-1N32-I-E-D-S-0 MTR series NEMA 34 stepping motor with series winding connection and encoder

ZA06B-0116-B175#0008 BM1/4000 servo motor with brake and 32k serial encoder

20BD481A0ANNNND0 PowerFlex 700 AC Drive 20B

20G11TF370AN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-D017 PowerFlex 520 7.5kW (10Hp) Power Module

372SPU47701V26 Quantum Concept 2.6 應用程序下載軟件

FRN 2.2E1S-7C 4.1 KVA 11 A 2.2KW 單相AC220V/50Hz/60Hz

A20B-2902-0070 A20B-2902-0070/02B

1492-SPM3D010-N MCB Supplementary Protector 1 A

軟啟動器 3RW40282TB04

SIMATIC 存儲卡 6ES7 954-8LC02-0AA0 4 MB

150-SD1NUD SMC-50 SOLID STATE MOTOR CONTROLLER 361A

1738-8CFGM23 ArmorPoint 8 Point Combination Module

1783-US6T2F Stratix 2000 6+2 port unmanaged switch

193-EXP-DIO-42-120 E300 120V AC Digital Expansion Module

20-750-NEMA1-F1 PF753 & PF755 FR 1 EMC CORES W PLATE

2090-CPWM7DF-16AF03 MP-Series 3m Length Power Cable

20AB-DB1-D PowerFlex 70 Resistor Kit

GA647IFESGRNUNLMT GCA iFIX Optn: ESig & ERec Unl I/O Run

GP646IFCLNTCRO010 GCP iFIX iClient Read Only 25 PK Keyless Runtime Version

IC600BF802RR 24-48Vac/dc Input Module (8 points)

IC647HSTCC1KM Calculation Collector for Historian - Standard Server 1000 Points (M4 Key)

IC647TBLCPVC001 Virtual Campus for Proficy Troubleshooter and Cause+ - 1 User

IC693MDL753CA Conformal Coated Output module, 12/24VDC POS logic, 32 points. Interfaceis Fujitsu connector.

IC756LDV000K-912 DV Development - Intel/Linux RedHat Op Sys, Korean, Version 9.12

Pico Controllers 1760-SIM INPUT SIMULATOR FOR 12 I/O DC PICO CONTROLLER

PLC-5/1771 System 1771-OD16K CONFORMALLY COATED, 120V AC ISOLATED OUTPUT MODULE

Distributed I/O 1791-0A32 BLOCK I/O, 120V AC, 32 POINT MODULE (32 OUTPUT)

Communications 1786-RPA CONTROLNET MODULAR REPEATER ADAPTER

Operator Interface 2706-PRIOK REMOTE I/O COMMUNICATION MODULE FOR 2706-P7X & P9X

Support 9701-VWSCWAS SUPT RENEWAL CONTRACT FOR 9701VWSCWAENE

Support 9324-RL0100ESR SUPT REINSTATEMENT CONTRACT FOR 9324RL0100ES

EtherNet/IP Products 2711P-K15C4B1 PV PLUS 1500, KEYPAD, ENET, AC PS, STD MEM

RSI Software Products 9301-2SE340PTU1R RSVIEW32 RUNTIME 1500-32K UPGRADE OUT-SUPT (PT)

RSI Software Products 9356-PRO2350U6R UPGRADE: OUT-SUPT: RSSQL PROF.300 TO PROF.5000 TAG

Motion Control F-4050-Q-H04AA MOTOR/ENCODER/BRAKE

4360-N 4360 WITH NEMA 4