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　PLC控制系統(tǒng)的設(shè)備與調(diào)試，觸及到各項作業(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)p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(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(tuán)體評論的基礎(chǔ)上綜合成為全體系調(diào)試計劃。

　　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，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。

　　②強(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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人機(jī)界面 6AV6545-0BA15-2AX0 TP170A 觸摸屏，藍(lán)色，6 英寸，320? 240

6ES78331FA130YE5

1497B-A13-M15-0-N Control Power Transber

1606-XLS480E Power Supply XLS 480 W Power Supply

1769-HSC CompactLogix High-Speed Counter Module

189-AB10 MCB Accessory Auxiliary Contact

194R-FN30-1753-PB Non-Fused 194R Disconnect Switch

2090-CPBM7DF-12AA20 MP-Series 20m Power and Brake Cable

2090-XXNPMP-16S12 MP-Series 12 m Length Power Cable

CBL-30-BT-10 Brake cable for MTR-3S or MTR-3N series servo motors with brake. 10 feet

GF-0200/MTI Connecting FlashCable to Chicago Dial Indicator Logic Series, Zipper c ompatible.

IC200TBX140 Tool box, Micro 40 and software. Includes (IC200UDR140) 24VDC In/Relay Out, requires 120/240VAC power, (IC200USB001) RS-232 option board with (2) 0 -10VDC analog in with Proficy software, manuals and cables (IC646MPM101)

IC646TBSPMPS400 Smart Process Monitoring Process+ server 400 loops

IC647NSE000 CIMPLICITY HMI SMARTEYE Driver

IC693ACC330 Base is discontiued. Use generic TBQC base IC693ACC329.

IC752BUU000 WinCfg & DataPanel Software Upgrade

IC800VMCP100 Power cable for 100 W to 750 W VersaMotion servo motors- 10 meter

SLC/1746 System 1746-OW16 RELAY OUTPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6189V-35HDD 3.5" HARD DISK DRIVE STANDARD

Application-specific products 1400-PD51A POWERMONITOR DISPLAY MODULE

Operator Interface 2711-B6C20L1 PV600 COLOR KEY&TOUCH, ENET & RS232 PRINT

Support 9301-2SE2400DER SUPT REINSTATEMENT CONTRACT FOR 93012SE2400DE

Support 9307-EM83PXS SUPT RENEWAL CONTRACT FOR 9307EM83PXENE

DeviceNet Products 1734D-IB8XOW8S 24 VDC 8 SINK IN 8 RELAY OUT, DNET COMMS, SPRING

RSI Software Products 9301-2SE250PTU5R RSVIEW32 WORKS 5K-100K UPGRADE OUT-SUPT (PT)

RSI Software Products 9358-BNT60U2 UPGRADE: IN-SUPT: RSBATCH 10 TO 60

Motion Control MPL-B330P-MK22AA MOTOR,SERVO,4.18 NM,5000RPM,MULTI,460V

Motion Control 2090-U3BB2-DM44 BREAKOUT BOARD, CN1, ULTRA3000 DRIVE MOUNTED

GFK-0646 C Programmer's Toolkit for Series 90-70 User's Manual

IC646CCW000 CIMPLICITY Client for Microsoft Windows

MSCPX-21280698 Marathon Exp CPU - 333 MHz AMD CPU, 128M, 6G, Win98, 2 ISA and 2 PCI/ISA expansion slots

PSPC-DC50-220L Prof Shop Floor SPC DC 50 User 220v

20BC015A0AYYANC0 PowerFlex 700 AC Drive 20B

20F11FC043JA0NNNNN PowerFlex 753 AC Packaged Drive

2198-KITCON-DSL CONNECTOR KIT, K5500, DSL

2711P-RBK10 PanelView Plus Accessory

280-PWRM35H-M35 ArmorConnect 3-PH Power Media trnk cable

CQM1-ID214 輸入32點(diǎn). 24V DC

1492-N3 TERM BLCK 2 Pole Side Jumper

通道高速計數(shù)模塊 6ES7350-2AH00-0AE0 FM350-2，8 通道高速計數(shù)模塊，最高 20KHz，8DO40pin 前連接器

行程開關(guān) 3SE53223SB23

TIA 博途 WinCC 選件 6AV2107-2KE00-0BD0 SIMATIC WinCC WebNavigator for Runtime Professional Powerpack 3 -> 5 Clients

1585J-M8HBJM-40 RJ45 Ethernet Media

1760-IB12XOW4IF PicoGFX Combination Module

188-K2B500 Miniature Circuit Breaker 50 A

194L-A12-1752 12A 194L Load Switch