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本文介紹了西門子 S7-200 SMART PLC、SMART LINE 觸摸屏以及 SINAMICS V20 變頻器在套標(biāo)機(jī)上的應(yīng)用，闡述了設(shè)備工藝流程、控制系統(tǒng)的配置選型、軟件設(shè)計(jì)和實(shí)現(xiàn)的功能。經(jīng)測(cè)試，該方案能完全滿足高速套標(biāo)機(jī)的各項(xiàng)技術(shù)要求，運(yùn)行穩(wěn)定，性能良好。
　　關(guān)鍵詞：S7-200 SMART SMART LINE SINAMICS V20 套標(biāo)機(jī)
1 引言
　　套標(biāo)機(jī)是一種將熱縮塑膠商標(biāo)桶卷自動(dòng)切斷，準(zhǔn)確套入容器的包裝機(jī)械，配合后熱收縮工序，將標(biāo)簽完好地固定于容器適當(dāng)位置。
　　上世紀(jì) 90 年代以來，我國的快速消費(fèi)品包裝工業(yè)得到了迅速發(fā)展，快速消費(fèi)品企業(yè)的生產(chǎn)集中度和自動(dòng)化程度在不斷提高，包裝設(shè)備在向大型化、快速化、高效化、自動(dòng)化方向發(fā)展。套標(biāo)機(jī)作為后段包裝技術(shù)含量較高的設(shè)備之一，其優(yōu)良的高速穩(wěn)定性能，獨(dú)特的靈巧化設(shè)計(jì)，人機(jī)協(xié)和的安全模式，得到了廣大客戶的充分肯定。套標(biāo)機(jī)的使用大大降低了套標(biāo)環(huán)節(jié)的人力物力，現(xiàn)已廣泛應(yīng)用于啤酒飲料、化工、醫(yī)藥等行業(yè)。
2 套標(biāo)機(jī)工藝原理
　　2.1 套標(biāo)機(jī)結(jié)構(gòu)
　　從工藝功能的角度進(jìn)行劃分，套標(biāo)機(jī)的結(jié)構(gòu)可分成以下 9 單元。并如圖 1 所示。
　　(1) 供料組：由變頻器帶動(dòng)供料電機(jī)旋轉(zhuǎn)，用以傳送標(biāo)簽?zāi)ち?
　　(2) 電眼架組：使用光纖電眼傳送信號(hào)，提供下標(biāo)伺服做定尺寸輸送，電眼位置可高低調(diào)整;
　　(3) 驅(qū)動(dòng)組：采用雙驅(qū)送料機(jī)構(gòu)，由下標(biāo)伺服電機(jī)驅(qū)動(dòng)。用于固定中心柱和下標(biāo)動(dòng)力傳動(dòng);
　　(4) 刀盤組：采用同步輪機(jī)構(gòu)，由伺服電機(jī)驅(qū)動(dòng)，當(dāng)進(jìn)瓶光電 7 給出信號(hào)時(shí)，切刀電機(jī)帶動(dòng)刀片旋轉(zhuǎn)一周將標(biāo)簽切斷;
　　(5) 刷下組：采用同步調(diào)整機(jī)構(gòu)，將刷下兩組傳送輪調(diào)整至中心柱下方與滾輪輕微接觸，待標(biāo)簽通過時(shí)以較高轉(zhuǎn)速將標(biāo)簽套入瓶子;
　　(6) 分瓶螺桿：將欲套標(biāo)瓶做等距分開，進(jìn)入帶瓶組，速度由變頻器控制，與輸送帶同步;
　　(7) 照瓶電眼：檢測(cè)是否有瓶子通過，當(dāng)有瓶子經(jīng)過時(shí)輸出訊號(hào)使切刀開始旋轉(zhuǎn)，左右位置可以調(diào)整;
　　(8) 輸送帶：使用變頻器調(diào)整輸送帶速度，以適用于各產(chǎn)能的速度匹配;
　　(9) 帶瓶組：采用兩側(cè)同步傳動(dòng)，標(biāo)簽高低與夾瓶定位各一只手輪調(diào)整，目的使瓶子輸送時(shí)不搖晃和控制套標(biāo)簽高度，速度由變頻器控制，與輸送帶同步。
　　2.2 套標(biāo)機(jī)工藝流程
　　當(dāng)輸送帶上有瓶子經(jīng)過照瓶電眼時(shí)，由伺服控制的切標(biāo)電機(jī)會(huì)將標(biāo)簽切斷，切標(biāo)完成后下標(biāo)伺服電機(jī)開始動(dòng)作，等到光纖信號(hào)到來時(shí)停止送標(biāo)，同時(shí)刷下料輪會(huì)將已經(jīng)切斷的標(biāo)簽刷下套入瓶子上，完成一次動(dòng)作。具體工藝流程如圖 2 所示。
硬件系統(tǒng)設(shè)計(jì)
　　3.1 硬件系統(tǒng)分析
　　本系統(tǒng)需要兩路高速脈沖輸出，分別控制切刀和下料伺服;一路高速計(jì)數(shù)器，用于控制切刀停止的位置，切刀停止位置應(yīng)不影響下標(biāo)的動(dòng)作，否則會(huì)造成堵標(biāo)。
　　以往套標(biāo)機(jī)的調(diào)速方式普遍采用電位器控制，用三個(gè)電位器分別控制輸送帶電機(jī)，定位皮帶電機(jī)和螺桿電機(jī)，供料電機(jī)的速度因?yàn)椴唤?jīng)常調(diào)節(jié)，所以用變頻器本身自帶的電位器調(diào)速。每次輸送帶速度變更時(shí)，都需要重新調(diào)節(jié)螺桿和定位皮帶的速度。調(diào)節(jié)時(shí)主要依靠調(diào)試人員的技術(shù)經(jīng)驗(yàn)和不斷的放瓶測(cè)試，才能使其線速度基本同步。本項(xiàng)目中設(shè)備的 I/O 清單如表 1 所示。
　　3.2 硬件系統(tǒng)設(shè)計(jì)
　　在本項(xiàng)目的電控方案中，選用西門子 SMART 解決方案，包括 S7-200 SMART PLC、SMART LINE 觸摸屏和 SINAMICS V20 變頻器。根據(jù)上述 I/O 需求，總共 12DI/12DO，選用 CPU ST40(24DI/16DO) 即可滿足需求。 SINAMICS V20 變頻器通過 USS 協(xié)議與 PLC 進(jìn)行通訊，不僅控制更加方便，也節(jié)省了 PLC 的 I/O 點(diǎn)。通過計(jì)算可將電機(jī)角速度轉(zhuǎn)化為輸送帶線速度。PLC 和觸摸屏通過以太網(wǎng)進(jìn)行通訊，只需要在觸摸屏上輸入生產(chǎn)速度，其他電機(jī)將會(huì)自動(dòng)進(jìn)行線速度同步。該方案大大縮短調(diào)試時(shí)間，降低調(diào)試難度。硬件結(jié)構(gòu)如圖 3 所示，主要硬件配置表如表 2 所示。
4 軟件系統(tǒng)設(shè)計(jì)
　　4.1 運(yùn)動(dòng)控制配置
　　S7-200 SMART 集成了三路 100kHz 的高速脈沖輸出，在本系統(tǒng)中切刀伺服占用 Q0.0，下標(biāo)伺服占用 Q0.1。打開 Micro/WIN SMART 集成的運(yùn)動(dòng)控制向?qū)?，配置軸 1 和軸 2，選擇單向相對(duì)脈沖，最大速度 50K，最小速度 1K，加減速時(shí)間 30ms，然后生成子程序。
　　4.2 高速計(jì)數(shù)配置
　　S7-200 SMART 集成了 4 路高速計(jì)數(shù)器，在本系統(tǒng)中只使用了高速計(jì)數(shù)器 HSC0，用于接收切刀的脈沖輸出，占用輸入點(diǎn) I0.0。打開 Micro/WIN SMART 集成的 HSC 向?qū)?，配?HSC0，選擇工作模式 0，預(yù)設(shè)值為 80000，當(dāng)前值為 0，計(jì)數(shù)方向向上，勾選 PV=CV 時(shí)中斷，步數(shù) 1，然后生成。當(dāng)切刀伺服啟動(dòng)后檢測(cè)到刀盤原點(diǎn)光電時(shí)，利用外部中斷快速更新高速計(jì)數(shù)器 HSC0 的當(dāng)前值和目標(biāo)值，目標(biāo)值等于當(dāng)前值加上偏置值。PV=CV 中斷時(shí)停止脈沖輸出，同時(shí)啟動(dòng)下標(biāo)伺服。
　　4.3 USS 通訊
　　S7-200 SMART 自帶庫文件 USS 協(xié)議，只需調(diào)用 USS 功能塊即可實(shí)現(xiàn) PLC 與西門子變頻器的通訊。通過 USS_INIT 進(jìn)行通訊參數(shù)初始化設(shè)置，包括與變頻器通訊的波特率，激活的變頻器個(gè)數(shù)，所占用的端口等，通信參數(shù)必須與變頻器設(shè)置的一致，否則無法通訊。每次通信參數(shù)的更改都需要重新執(zhí)行此命令，本項(xiàng)目中的通訊參數(shù)固定，所以只上電執(zhí)行一次。通過調(diào)用 USS_ CTRL 指令可以直接控制變頻器的啟動(dòng)、停止以及頻率，每條 USS_CTRL 指令只能控制一臺(tái)變頻器。
　　4.4 SINAMICS V20 變頻器的配置
　　設(shè)置V20變頻器的連接宏為Cn010—USS控制，分別設(shè)置螺桿、皮帶、供料、輸送帶變頻器地址 P2011[0] 為 1、2、3、4。同時(shí)，設(shè)置應(yīng)用宏為 AP030—傳送帶控制，SINAMICS V20 可自動(dòng)配置適合傳送帶應(yīng)用的控制參數(shù)。
 

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Process Control 9358-PBPCNT03ENE RSBATCH NT FOR PROCESLGIX PC BASED PHASES 03 UNITS

Operator Interface 2711P-RBB12 PV PLUS 1250 KEY/TOUCH REPLACEMENT BEZEL

Support 9355-JBOXENS SUPT RENEWAL CONTRACT FOR 9355JBOXEN

Support 9351-HPUSS SUPT RENEWAL CONTRACT FOR 9351HPUS

ControlNet Products 1786-FS60 200 MICRON CABLE ASSEMBLY 60 METERS (196.8 FT)

RSI Software Products 9301-2SE2400DEU1 RSVIEW32 WORKS 1500-32K UPGRADE IN-SUPT (DE)

RSI Software Products 9355-WABGWEU2 UPGRADE: IN-SUPT: WINLINX TO RSLINX GATEWAY

Motion Control MPL-A310P-SK22AA MOTOR,SERVO,1.58NM,5000RPM,SINGLE,230V,3.1KG

Motion Control 2090-DANPT-16S03 CABLE, NON-FLEX, MTR PWR, CABLE-MTD CONN, 16AWG, 0

BC647MPS050 Logic Developer PLC Standard Edition - 50 user pack with Proficy GlobalCare Complete and 50 hardware keys.

IC5005TBN0000 15" Inbligence Industrial PC, Perbance Series WinNT

IC800MCUB12160XE Stepping MotorCube 50 oz-in, Pulse/Direction, Encoder Feedback

OC647IFDBPKM iFIX Optn: Database Pack

20AD022A3AYNAEG1 PowerFlex 70 AC Drive 22 A at 15 Hp 20A

20DC205A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ANF034JA0NNNNN PowerFlex 755 AC Packaged Drive

25C-D4P0N114 PowerFlex 527 1.5kW (2Hp) AC Drive

280-PWRM22A-M4 ArmorConnect 4 Meter M22 Patchcord

FX1S-20MT-D 直流主機(jī)12入/8出 晶體管輸出

6ES7 332-5HB01-0AB0 模擬量輸出模板,2通道

cRIO-9068

PCM-9571

MOXA 正品 CP-132I

C79458L7000B126

GTB6022-13L

BP-0604P

ROBO-8779VG2A

1492-SPM2D150 MCB Supplementary Protector 15 A

軟啟動(dòng)器 3RW30462BB14

ABICTAE0000/SER 10.5 Inch Color TFT, TCP Label, 110VAC, with AB Serial Cable

GC646PCMKIT GlobalCare Complete for Proficy Change Management Starter Kit (1 user, Scheduler)

HE697BEM600 Discontinued Part. Check with GE IP on migration path.

IC630MDL366RR Analog Output Module, 4-20mA (2 channels)

IC647HSTSS5KM Historian Standard Server 5000 Points (M4 Key)

IC660BLC001 Cable w/Connectors Alpha 9823 15 In (Qty 3)

IC695ALG728 Analog Output HART Module, 8 channels,that is configurable for voltage, current, current/HART configured for Current: 0 to 20mA, 4 to 20mA; Voltage: +/- 10VDC, 0 to 10VDC per channel non isolated. Up to 16 bit resolution. Requires high capacity ter

IC756WDV009K-23 DV Development Sys Visual Basic, Korean, Version 2.3

CompactLogix System 1769-CLL1 1 FT (305 MM) LEFT-TO-LEFT BUS EXPANSION CABLE

PLC-5/1771 System 9399-RL53GRDE RSLOGIX 5 GETTING RESULTS GUIDE(GERMAN)

Distributed I/O D1794-6.5.3 FLEX I/O REMOTE I/O ADAPTER MOD. USER MANUAL

Operator Interface 2711P-T6M5A PV PLUS 600 GRAYSCALE, TOUCH, RS232, AC PS

Support 6404-DDMCS SUPT RENEWAL CONTRACT FOR 6404DDMC

Support 9358-PLTM2100R SUPT REINSTATEMENT CONTRACT FOR 9358PLTM2100ENE

Support F1784-CPCIDS FIRMWARE UPGRADE FOR 1784-CPCIDS COMMUNICATION MOD

RSI Software Products 9301-2SE2200DEU1 RSVIEW32 WORKS 150-300 UPGRADE IN-SUPT (DE)

RSI Software Products 9701-VWSB000AJPE RSVIEW SE STATION UNLIMITED DISPLAY (JAPANESE)

RSI Software Products 9399-APSIE SLC 500 APS IMPORT/EXPORT UTILITY USER MANUAL

Motion Control 2098-DSD-HV220 HIGH VOLTAGE DRIVE, 47A/94A, ULTRA3000

ABK3D200C2P/DVN QUICKPANEL 6" TFT W/DVN

IC220TBK123 I/O TERMINAL STRIP, 12 POSITION SPRING STYLE W/COLOR, OUTPUT, QTY 10

IC752DPH000RR Datapanel H, 640x200 LCD with CCFT backlight. Text, bitmaps, bar graphs, real time clock. Includes integrated keypad. No touch capability.

MTR-3S33-G-R-B-E-S MTR series servo motor with resolver and brake and shaft seal

ZA06B-6050-K120 Motor encoder connector kit for B0.5/3000 motor

20BE052A3AYNAND0 PowerFlex 700 AC Drive 52 A 50 Hp 20B

20G14NF050JA0NNNNN PowerFlex 755 AC Packaged Drive

25-RF011-AL PowerFlex 520 10.7A 230V EMC Filter Kit

2711P-RTBAC3 PanelView Plus Accessory

FRN75G11S-4CX 114KVA 150A 75KW 3相AC380V/50Hz/60Hz

AH22-SZR(G,Y,W,C,O)M 方30×30mm指示燈自帶變壓器AC220V-6.3V,顏色同上

ATV-58HD12M2 5.5

USB-9421

6GK1541-2BA00

DPS-350NB-1

SUN 375-3536

PCISA-C400R-RS-R20

TPC-1261H-A1E

1492-SPM1B030-N MCB Supplementary Protector 3 A

6ED1052-1HB00-0BA5 LOGO!24RC 24VAC/DC 8DI/4DO,繼電器輸出，實(shí)時(shí)時(shí)鐘

20AC011A3AYNANC0 PowerFlex 70 AC Drive 20A

GA647IFSTRNUNLMT GCA iFIX Std HMI Unlmt Run

GP647IFPLSR00150 GCP iFIX Plus SCADA 150 I/O Srv

IC600BF942RR -10Vdc to +10Vdc Analog Output Module (4 channels)

IC647HSTCR50KM Collector Redundancy Option for Historian - Standard Server 50000 Points (M4 Key)

IC647TPR935 CIMPLICITY HMI ProServer 35,000 I/O Runtime System

IC693PTM100CA Conbal Coated Power Transducer Module

IC756MDV001J-97 DV Development - Alpha OpenVMS Addt'l User, Japanese, Version 9.7

MicroLogix 1000/1761 System 1761-NET-DNI DEVICENET INTERFACE (DNI)

PLC-5/1771 System 1771-NBTC HIGH RESOLUTION ISOLATED ANALOG MODULE

Distributed I/O 1792D-CB18 MAXUM ROUND MEDIA 18MM BASE, PASSTHRU FOR DNET

Communications 9351-HPUS INTERCHANGE FOR HP-UX

Operator Interface D6190-6.5.24 CONTROLVIEW GETTING STARTED

Support 9356-STD2400S SUPT RENEWAL CONTRACT FOR 9356STD2400

Support 9392-CDRSFRE DATADISC ENGLISH/FRENCH BUNDLE

RSI Software Products 9323-L2300DU UPGRADE: IN-SUPT: 6200-2 BOTH TO AI-2 BOTH

RSI Software Products 9301-2SE3500KOU5 RSVIEW32 RUNTIME 5K-100K UPGRADE IN-SUPT (KO)

RSI Software Products 9356-SQLSAPADENE RSSQL FOR SAP SOLUTIONS ADDITIONAL SAP MODULE

Motion Control TL-A230P-BJ32AA MOTOR, SERVO, 1.3NM, 5000RPM, 17BIT SERIAL FEEDBAC

44A738935-001 Cable, Motion Mate MCS300 Series Interface Cable

IC200CHS002 I/O CARRIER BOX STYLE

IC694MDL340 OUTPUT MODULE 120 VAC 0.5AMPS 16 POINTS

MSI-UNIV-WEB-25 Universal Web Client(RTIP / Dashboard / Web / Excel Addin) 25 Pak

VSPC32-OPC50 OPC Client Option includes VisualSPC Importer (licensing is per client PC), Support for 26 to 50 Points/Tags.

20BD040A0AYNANC0 PowerFlex 700 AC Drive 40 A at 30 Hp 20B

20G11JC1K1JN0NNNNN PowerFlex 755 AC Packaged Drive

22D-D010N104 PowerFlex 40P- 4 kW (5 HP) AC Drive

140NOE77101 Quantum TSX QUANTUM ETHERNET 10/100 BASE T100FX

290D-FBZ-G2 Direct Online Starter

E53-AZ01 NEW RS232通訊板

1761-NET-DNI DeviceNet 網(wǎng)絡(luò)接口模塊

PXIe-2569

AVCLAN PS10311 PC113-A

C79298-A3238-B903

MIO-AUDIO 888

D1280E1-PCI

Q80BD-J71LP21-25

1492-N901 TERM BLCK Marking Cards for HM

安裝導(dǎo)軌 6ES7390-1AJ30-0AA0 安裝導(dǎo)軌，830 mm