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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(lái)，我國(guó)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(guò)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(kāi)，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(guò)，當(dāng)有瓶子經(jīng)過(guò)時(shí)輸出訊號(hào)使切刀開(kāi)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(guò)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(kāi)始動(dòng)作，等到光纖信號(hào)到來(lái)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(guò) 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(guò)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(guò)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(kāi) Micro/WIN SMART 集成的運(yùn)動(dòng)控制向?qū)В�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(kāi) 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(kù)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(guò) 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(wú)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(guò)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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SOL6M4A Y7190-02

1492-PRINTCOLLECT Clear Mark Printer Ink Collector

接口模塊 6ES7461-3AA00-7AA0 用于 IM461-3 終端連接器

2098-DSD-030-DN Ultra 3000 Servo Drive

G-C497 GagePort to Burr-Brown Vax Keyboard Wedge

GFK-2200 Target ARS Hardware Manual (requires GFK-2205 Programming Manual)

IC220TBK082 I/O TERMINAL STRIP, 8 POSITION SPRING STYLE, QTY 10

IC647FSHC FSH:Fisher CHIPS (UNIVOX and PROVOX)

IC647SDB001 Scheduler Extra Server Database

IC693MDL644RR 24 Vdc Input, Negative Logic (16 Points)

IC756DVE010E-99 EO GECK (Graphical Editor Construction Kit) - Intel x87, English, Vers ion 9.9

MSI-QUAL-5-43 Quality Mang Clients 5 Pack-43

PLC-5/1771 System 1771-A3B1K CONFORMALLY COATED, I/O CHASSIS ASSEMBLY, 12 SLOT

Distributed I/O 1790D-T0V16 DNET LDX I/O,24VDC,16 SINK OUT BASE, TERMINAL BLK

Communications 1770-CD7 DATA HWY TWINAXIAL CABLE, 700 FT/213 M

Operator Interface 2711E-UK14EK10 PANELVIEW 1400E KPD TO 1000E KPD MIGRATION KIT

Support 9305-RSVADFCESS SUPT RENEWAL CONTRACT FOR 9305RSVADFCES

Support 1754-PCSR SUPT REINSTATEMENT CONTRACT FOR 1754PCS

EtherNet/IP Products 1788-ENBT ETHERNET/IP LOGIX DAUGHTERCARD

RSI Software Products 9301-2SE3400KOU2 RSVIEW32 RUNTIME 300-32K UPGRADE IN-SUPT (KO)

RSI Software Products 9515-RSAAMPRVENE RSMACC AUTO ASSET MGMT, PREVENTIVE MAINT

Motion Control 1326AB-B430E-M2K4L MOTOR,SERVO,460V,6.6NM,3000RPM,MULTI,BRK,IP67

3414-128-C Greyline OS, 2 Line, (20) 9MM Chars, VFD, Quick Connect, 128K Memory W/Clock/Date, NEMA 4

HMI-BEZ-201 BEZEL 5" STAINLESS STEEL

IC693ACC350 Redundant Power Supply Adapter (RPSA) Module. The RPSA replaces the power supply on a CPU base or expansion base and connects to a Redundant Power Supply Base.

QPL21100C2P QUICKPANEL COLOR 12.1" TFT

TGT-DI0L-32-0RR Target Digital I/O 16 Inputs and 15 Inputs/Outputs

20BC5P0A0AYNAND0 PowerFlex 700 AC Drive 5 A at 2.2 kW 20B

20F1ANE242AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-D2P3H204 PowerFlex 40- 0.75 kW (1 HP) AC Drive

140ACI03000 Quantum 模擬量輸入,單極性高速,8通道,4-20mA或1-5V

284E-FVD4P0Z-10-RR-3-DB1-EMI EtherNet Variable Frequency Drive

E2E-X1R5E1 1.5mm,電感式,三線,常開(kāi) 100mA NPN電源:10-30VDC圓M8

AX10488-2 2米GP-IB線

PXI-5122

HPCI-14S12U

W26361-W83-X-02

GXT145 PCI-E 10N7756

CONTEC MB-486(PS)

P6F135

1492-MCGAT220 Ground Fault Circuit Breaker

1494V-H2 Disconnect Switch Handle

軟啟動(dòng)器 3RW44656BC35

CFDA-3WPB-0140-AZ This cable has been replaced by cable CFDA-7WPB-0140-AZ

GF-3920R Connecting FlashCable to Fischer Scientific XT.

IC200UDR020 VersaMax Micro 20 point PLC,(12) 24VDC In, (8) Relay Out, 24VDC Power Supply. (1) serial port and (1)optional communication port. Requires Machine Edition 5.7 or higher. Battery (IC200ACC414) is required for data retention. Battery not included.

IC646TRT935 35,000 I/O Point Runtime System

IC647PATH110 Proficy PAT - Historian. The capability is to store spectra data from the driver into the Proficy Historian. This for a two driver

IC693APU305 I/O Processor Module

IC752PBI100RR PC/104 Profibus Card

IMC-105E-1-DRR Stepping Motor Controller, Enhanced, 5 Amp

SLC/1746 System 1746-P6 POWER SUPPLY - RACK MOUNT

Industrial Computers 6189V-MMA17 MNTG ADAPTER FOR CONVERTING 6185-D OR H TO 1700M

Application-specific products 1404-M505B-DNT MASTER MODULE - PQ 24V P/S DNET COM

Operator Interface 2711-K10C16 PV1000 COLOR KEY, DF1 & RS232 PRINT

Support 9301-2SE3200FRS SUPT RENEWAL CONTRACT FOR 93012SE3200F

Support 9380-RSBVB10000R SUPT REINSTATEMENT CONTRACT FOR 9380RSBVB10000

DeviceNet Products 1792D-16BVT0D 16 SINK/SOURCE INPUTS, 8 CONNECTORS

RSI Software Products 9301-2SE3204 REVIEW32 RUNTIME 300 WITH RSLINX SINGLE NODE

RSI Software Products 9358-BPMGR03U1 UPGRADE: IN-SUPT: RSBW BATCH PRD MGR 1 TO 10 SERV

Motion Control MPL-B4530F-RK24AA MOTOR,SERVO,8.36 NM,2800RPM,RSLVR,460V,BRK

Motion Control 2090-SCVP10-0 SERCOS FBR CABL,CONN,STANDARD PVC JKT,PLASTIC 10.0

GPWPB01M-C49 GP PRO Software Version 5.0

IC646MPP050 Logic Developer - PLC Professional - 50 Pack

MTR-1337-N-A-E-0 Stepping Motor Nema34, Parallel Wdg

QPJ-PSM-201 Communication Adaptor Module for 6 inch QuickPanel 4s

20BC037A3AYNANN0 PowerFlex 700 AC Drive 20B

20F11NC085JA0NNNNN PowerFlex 753 AC Packaged Drive

22-HIM-H10 PowerFlex 1 m HIM Cable

2711P-RGT12SP PanelView Plus 7 Protective Overlay

280S-MTR22-M6 ArmorStart Spare Parts

C200HW-COM06-EV1 一個(gè)RS422/485端口和一個(gè)RS232C端口 通信協(xié)議宏功能

PCL-711S 經(jīng)濟(jì)型數(shù)據(jù)采集卡,40KHzA/D,12BIT,8SE;1ch12BIT D/A;16ch DI/DO;帶端子板

PCI-6602

GX1-300B-85-2.0

PCA-6114P10

YM-2821C

IB950EF

SOLIOS eV-CL Y7367-00

1492-LD4 IEC Term Blck 6.1x76x52.2mm Spr Clp

1494F-FS60 60 A Fuse Block

軟啟動(dòng)器 3RW44352BC34

BC647OEMK5M4 OEM Edge 5-pack M4 Keys includes 5 physcial M4 keys

GC647PATLT00 "Proficy PAT - Process Analytical Software Suite, Special Purpose 2 - Assist Support"

IC200MDD849 Mixed output relay 2.0 amp per point isloated 8 point / input 120VAC isolated 8 point

IC646NSL025 Proficy SQL 2000 - 25 Client Access License

IC647MDA150 View Development/Runtime 150 I/O with USB Hardware key

IC675PDO161 Profibus Station IP67 24VDC Positive Logic 16 Outputs 0.5A

IC697MDL940 Relay Output, Signal, 2 Amp (16 Points)

IC800SSD107S1 7.2 amp 115/230 VAC S2K servo drive for S-series motors

ControlLogix/1756 System D1756-6.5.7 U MNL CONTROLOGIX GATEWAY

Industrial Computers 6182H-15KEH6B VVCE 1500, KEYPAD, EXT MEM, RIO/DH, AC

Process Control 1757-DNBUL05 DEVICENET USAGE LICENSE, 5 DNB MAX

Operator Interface 2711-K3A2L1 PV300 MONOCHROME KEY, DH485 & RS232 PRINT

Support 9326-AD25US SUPT RENEWAL CONTRACT FOR 9326AD25UENE

Support 9371-EDESI3R SUPT REINSTATEMENT CONTRACT FOR 9371EDESI3

ControlNet Products 1797-BOOT CONTROLNET EX BOOT INSULATOR KIT (50 PIECES)

RSI Software Products 9301-2SE240KOU5R RSVIEW32 WORKS 5K-32K UPGRADE OUT-SUPT (KO)

RSI Software Products 9358-BA30U1 UPGRADE: IN-SUPT: RSBIZWARE ARCHIVER 03 TO 30

Motion Control MPL-A4520K-MK22AA MOTOR,SERVO,6.10 NM,4000RPM,MULTI,230V,6.8KG

Motion Control 2090-UXNPAMP-10S30 CABLE,NOGRF50X,MOTOR POWER,MP,10 GAUGE,30M

CBL-207 OMRON Host Link Cable

IC640HWC716 Logicmaster 90-70 Ethernet TCP/IP for Windows NT/95 w/ InfoLink, Stn Mgr and Mini-Converter cables

IC800SLCPV050 Power Cable, 1000 W SL Servo Motor, 5 Meters

OC647IFXPENWK iFIX for Embedded XP Networking Option

20AD5P0A3NYYAEG0 PowerFlex 70 AC Drive 5 A at 3 Hp 20A

20DD027A3EYNACANE PowerFlex 700S AC Drive 20D

20P41AD010RA0NNN PowerFlex 460V AC 5 HP DC Drive

2711C-RJ422 PanelView Component Accessory

280-PWRM24E-M14 ArmorConnect 3-PH Power Media drop cable

SRS1-T 端子模塊的終端器

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