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　PLC控制系統(tǒng)的設(shè)備與調(diào)試，觸及到各項(xiàng)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(chǎng)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(duì)現(xiàn)場(chǎng)經(jīng)常出現(xiàn)的設(shè)備、調(diào)試相關(guān)問(wèn)題，提出評(píng)論定見(jiàn)和解決計(jì)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(huì)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(duì)體系工藝流程，特別是工藝對(duì)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(duì)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(dòng)力接線圖，并與什物相對(duì)照，以及時(shí)發(fā)現(xiàn)過(guò)錯(cuò)并糾正。

　　(4)在全面了解規(guī)劃計(jì)劃與PC技能材料的基礎(chǔ)上，列出PC輸入輸出點(diǎn)號(hào)表(包含內(nèi)部線圈一覽表，I/O所在位置，對(duì)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(duì)邏輯雜亂的部分輸入、輸出點(diǎn)制造時(shí)序圖，一些規(guī)劃中的邏輯過(guò)錯(cuò)，在制造時(shí)序圖時(shí)即可發(fā)現(xiàn)。

　　(6)分子體系編制調(diào)試計(jì)劃，然后在團(tuán)體評(píng)論的基礎(chǔ)上綜合成為全體系調(diào)試計(jì)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(lèi)型、數(shù)量、規(guī)范，其功用是否無(wú)缺待實(shí)驗(yàn)室及現(xiàn)場(chǎng)調(diào)試時(shí)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(cè)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(jí)與PLC電壓選擇相契合后，按開(kāi)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(cè)，此刻即可進(jìn)行各項(xiàng)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(duì)程序的了解將逐漸加深，為現(xiàn)場(chǎng)調(diào)試作好了準(zhǔn)備，同時(shí)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：

　?、倌７罗k法：按規(guī)劃做一塊調(diào)試板，以鈕子開(kāi)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(shí)的回來(lái)信號(hào)節(jié)點(diǎn)。其長(zhǎng)處是具有模仿的真實(shí)性，可以反映出開(kāi)關(guān)速度差異很大的現(xiàn)場(chǎng)機(jī)械觸點(diǎn)和PLC內(nèi)的電子觸點(diǎn)相互銜接時(shí)，是否會(huì)發(fā)作邏輯誤動(dòng)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。

　?、趶?qiáng)置辦法：使用PLC強(qiáng)置功用，對(duì)程序中觸及現(xiàn)場(chǎng)的機(jī)械觸點(diǎn)(開(kāi)關(guān))，以強(qiáng)置的辦法使其“通”、“斷”，迫使程序工作。其長(zhǎng)處是調(diào)試作業(yè)量小，簡(jiǎn)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(chǎng)節(jié)點(diǎn)“通”、“斷”，會(huì)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(chǎng)調(diào)試的經(jīng)驗(yàn)，對(duì)部分重要的現(xiàn)場(chǎng)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(zhǎng)互補(bǔ)。邏輯驗(yàn)證階段要著重逐日填寫(xiě)調(diào)試作業(yè)日志，內(nèi)容包含調(diào)試人員、時(shí)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(shù)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(shí)征求規(guī)劃者的定見(jiàn)，力求準(zhǔn)確表現(xiàn)規(guī)劃要求。
 

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1771-NOC 1771 Analog Module

193-EC5FF E3 Plus 28-140 A Overload Relay

198E-C2S Plastic Enclosure, 250mm x 125mm x 125mm

2090-CPWM4E2-10TR MP-Series 0.5m Length Transition Cable

2094-BNCON-1 Kinetix 6000 Connector Set

DEMOCD00050 Knowledgebase CD

GFK-0845 Genius I/O Micro GENI Board User's Manual

IC210EAR008 Expansion unit, AC (85 to 264VAC) Power Source, (4) AC in/(4) out (Relay, 8 Amp)

IC647AUR001 PA Universal Reporting Client

IC647PRTEE005C Proficy Portal Enterprise Edition Client Pack 5 Users (M1 Key)

IC693CPU331LT CPU 331 Module (16K Bytes) (LT)

IC754VKI12MTD Starter Kit/ 12 Inch View Mono Interm/ 24VDC

MSI-DASHBOARD-5-43 Dashboard Client 5 Pack Ver4.3

SLC/1746 System 1746-RL46 REPLACEMENT OCTAL LABEL KIT FOR CTLG # 1746-ITB16

Distributed I/O 1734-IK 24 VDC INCREMENTAL ENCODER MODULE

Application-specific products 9307-64MGDBCENE RSEMETRIX MGR(9-64 METERS),W/1MSSQL CLIENT LIC.

Operator Interface 2711-CBL-HM10 10METER RS232 CABLE, PV300MICRO TO MICROLOGIX

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Support 9510-PB10000ENR SUPT REINSTATEMENT CONTRACT FOR 9510PB10000EN

DeviceNet Products 1771-SDN 2-CHANNEL DEVICENET SCANNER MODULE

RSI Software Products 9301-2SE3350KOE RSVIEW32 RUNTIME 5K (KOREAN)

RSI Software Products 9307-EM83PXENE RSENERGYMETRIX 3RD PARTY OPC (0 - 8 METERS)

Motion Control MPL-B980B-SJ22AA MOTOR,SERVO,122.0NM,1000RPM,SINGL,460V

Silver Series 1398-DDM-075 DRIVE,75A PEAK, ULTRA 200

HE690CBL105 Ribbon cable for HE690RLY160, 5 foot.

IC646TPR915 Pro Server 1,500 I/O Point Run Time System

QM4204ROA QUICKMARQUEE 4 X 20 4.8" OR 8 X 40 2.1" RED

ST-3644 STXi analog b module 4 Channels, 0~5Vdc, 14-bit

20BC140A0ANNANC0 PowerFlex 700 AC Drive 20B

20F14NF050JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-D2P3H204 PowerFlex 4- 0.75 kW (1 HP) AC Drive

140CPS52400 Quantum 電源, 125 VDC, 冗余, 8A

284D-FHD7P6B-25-CR-3-SB DeviceNet Variable Frequency Drive

CJ1W-OA201 8點(diǎn)可控硅輸出單元

1492-RTB10N 10-Pole Screw Style Rtb Plug

WinCC 上位監(jiān)控軟件 6GK1716-1PB62-3AA0 PG-1613 驅(qū)動(dòng)

變送器 3RS17031CD00

1497A-A2-M6-1-N Control Power Transber

1606-XLP60BQ AC or DC In 12VDC Out 54W Power Supply

1768-CNBR CompactLogix L4X Redundant CNet Module

188-K4C100 Miniature Circuit Breaker 10 A

194R-30-HDWR 194R Replacement Mounting Hardware

2090-CPBM7DF-10AA25 MP-Series 25m Standard Cable

2090-XXNPMP-10S30 MP-Series 30 m Length Power Cable

CBL-12-MPS-20 Power cable for MTR-1221-*-D and Power cable for MTR-1231-*-D stepping motor connected to S2K. 20 feet

GC647SSM005 GCScheduler Shop Floor Server 5 users

IC200PWR012 Isolated 24 VDC Expanded 3.3V Power Supply

IC646TBLSS1000 Proficy Troubleshooter for Inbligent Historian for Hist 1000 Points

IC647NGJ000 CIMPLICITY HMI Johnson Controls N2 Communications

IC692MAA541RR 16 AC b/ 12 Triac Output 120 Vac PS

IC698CRE020 PACSystems RX7i High Availability 700mHz CPU

IC800VMCB030 Motor power and brake power cable for 200 W to 750 W VersaMotion servo motors- 3 meter

SLC/1746 System 1746-IN16 INPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6180W-15KPXPH VERSAVIEW 15-INCH WORKSTATION, KEYPAD

Application-specific products 6556-PA0PM CLUTCH/BRAKE KIT W/ARMED CONTINUOUS PUSHBUTTON

Operator Interface 2711-K5A9L3 PV550 MONOCHROME KEY, RS232 (DH485) & RS232 PRINT

Support 9301-2SE2200JPR SUPT REINSTATEMENT CONTRACT FOR 93012SE2200JP

Support ABTS-W102R ABT-SW102 PATHFINDER SW SUPPORT REINSTATEMENT

ControlNet Products D1785-6.5.14 CONTROLNET PLC5 PROG. CONT. USER MANUAL

RSI Software Products 9301-2SE250ESU4R RSVIEW32 WORKS 150-100K UPGRADE OUT-SUPT (ES)

RSI Software Products 9358-BERP03U2 UPGRADE: IN-SUPT: RSBW BATCH ERP 3 TO 10 SERVER

Motion Control MPL-B310P-MJ22AA MOTOR,SERVO,1.58 NM,5000RPM,MULTI,460V,3.0KG

Motion Control 2090-XXNPMP-16S25 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,16 GAUGE,25M

GC646TDV150 Proficy GlobalCare Complete for Server 150 I/O Develop/Runtime System

IC641SWP065 Motion Programmer Software

IMC-105P-1-D Stepping Motor Controller, Enhanced, DeviceNet, 5 Amp

PSPC-DC100 Prof Shop Floor SPC DC 100 User

20BB9P6A0AYNBNC0 PowerFlex 700 AC Drive 9.6 A 3 Hp 20B

20DJ248A3NNNACGNE PowerFlex 700S AC Drive 20D

2198-H040-AD-T K5500 FR1,2 AC,DC bus conn

2711P-K7C4D9 PanelView Plus Terminal

280-PWRM35F-M2 ArmorStart Three-Phase Power Media

CP1H-XA40DR-A XA型主單元，24入16點(diǎn)繼電器輸出. 高速計(jì)數(shù)50/100khz 4軸 .usb端口編程.集成模擬量4入2出.

1492-MS8X12V1-10 Connection Products

模擬量輸入/輸出模塊SM 6ES7 331-1KF01-0AB0 AI/8，電壓、電流、電阻、PT100，光電隔離，40pin前連接器

行程開(kāi)關(guān) 3SE53220SD21

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1585J-M8CBJM-32 RJ45 Ethernet Media

1756-PSCA2K ControlLogix Adaptor

188-K1D100 Miniature Circuit Breaker 10 A

194E-Y25-1756-6N 25 A 194E Load switch

2090-CFBM7E7-CDAF20 MP-Series 20 m Length Feedback Cable