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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)�損壞設(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)問題，提出評(píng)論定見和解決計(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：

　　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(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，力求準(zhǔn)確表現(xiàn)規(guī)劃要求。
 

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140DAI54300 Quantum 開關(guān)量AC輸入,16點(diǎn),115VAC,8點(diǎn)成組隔離

284D-FVD2P3B-10-RR-3-DB-SB-EMI DeviceNet Variable Frequency Drive

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1492-RXIMTR2024-16R Mech Relay Digital Interface Module

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6ES78220AA030YA5

1497B-A10-M14-3-N Control Power Transber

1606-XLS120EA Power Supply

1769-AENTR 1769 Ethernet/IP Adapter

188-K4D030 Miniature Circuit Breaker 3 A

194R-C30-1753 194R Disconnect Switch

2090-CPBM7DF-10AF25 MP-Series 25m Continuous-Flex Cable

2090-XXNPMP-14S15 MP-Series 15 m Length Power Cable

CBL-14-ED-20 Encoder cable for MTR-1235 or MTR-1300 or MTR-1400 or MTR-1N series splashproof stepping motors connected to IMC or S2K. 20 feet

GCREINSTATEMENT GlobalCare Reinstatement Fee

IC200TBM002 I/O auxilary box style

IC646TBLSS50K Proficy Troubleshooter for Inbligent Historian for Hist 50000 Points

IC647NME000 CIMPLICITY HMI MITSUBISHI MELSEC Communications

IC693ACC308 Rack Adaptor Bracket/ Series 90-30 10 Slot to 19 inch (Front Mount)

IC750CTR100RR PANELWARE VT 100 Panel Controller

IC800VMCB3030 Motor power and brake power cable for 3 kW VersaMotion servo motor- 3 meter

SLC/1746 System 1746-OAP12 HIGH CURRENT AC OUTPUT MODULE FOR PRGRMMABLE CTRLR

Industrial Computers 6155R-7PXPH VERSAVIEW NON-DISPLAY COMPUTER, 7 SLOT

Application-specific products 6556-SCBK3DC OMEGA - 5/03 CLUTCH/BRAKE DC KIT

Operator Interface 2711-T5A9L1 PV550 MONO TOUCH, RS232 (DH485) & RS232 PRINT

Support 9301-2SE2300FRR SUPT REINSTATEMENT CONTRACT FOR 93012SE2300FR

Support 9307-64MGDBPS SUPT RENEWAL CONTRACT FOR 930764MGDBPENE

DeviceNet Products 1734-ADN 24V DC DEVICENET ADAPTER

RSI Software Products 9301-2SE250JPU1R RSVIEW32 WORKS 32K-100K UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-BNT10U1 UPGRADE: IN-SUPT: RSBATCH 03 TO 10

Motion Control MPL-B320P-MJ22AA MOTOR,SERVO,2.94 NM,5000RPM,MULTI,460V,4.0KG

Motion Control 2090-XXNPY-16S15 CABLE,NON-FLEX,MOTOR POWER,Y,16 GAUGE,15M

GFK-0265 Series 90-70 Programmable Controller Reference Manual

IC641VPP710 VersaPro Professional Edition 10 Pack - Windows Programming Software for Series 90-70, Series 90-30, and VersaMax PLCs

MMR-B00P-1M-0 Target 1Mb BBRAM Memory Card

PSPC-DC25/E Prof Shop Floor SPC DC 25 User w/ eSig

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20DM590A0NNNBCANE PowerFlex 700S AC Drive 590 A 560 kW 20D

2198-H070-ADP-T K5500 FR3 AC,DC,control conn

2711P-RAK15 PanelView Plus 1500 Cutout Adapter

280-PWRM35G-M25 ArmorConnect 3-PH Power Media trnk cable

CQM1H-SCB41 串行通訊板 RS-232C 一個(gè)/RS422/485一個(gè)

1492-MUA4-A13-A17 1774 - 1756 Conversion Mounting Assembly

通訊處理器CP 6ES7 340-1CH02-0AE0 CP340，標(biāo)準(zhǔn)串行通訊模塊，RS422/485 接口，最高 19.2kbit/s,9 針 Sub-D 型接口

行程開關(guān) 3SE53220SJ22

TIA 博途 WinCC 選件 6AV2107-0EB00-0BB0 SIMATIC WinCC Server for Runtime Professional

1585J-M8HBJM-0M2 RJ45 Ethernet Media

1756-TBE ControlLogix Deep Terminal Block Housing

188-K1D400-N Miniature Circuit Breaker 40 A

194E-Y40-1756-6G 40 A 194E Load switch

2090-CFBM7E7-CEAF25 25 m Length SpeedTec Extension Cable

2090-UXNPBMP-10S01 MP-Series 1 m Length Power Cable

BC647CSCEMK QuickPanel Control software with Proficy GlobalCare Complete and a hardware key

GC647IFPLSRUNLMT GCC iFIX Plus SCADA Unlmt Srv

IC200CBL655 Mitsubishi Fx 25-pin, RS-422 Cable to DataPanel 45/65/85

IC646MPSS99 Logic Developer PLC Standard Unlimited Seat Site License

IC647IFSTDV00075K iFIX Standard HMI 75 I/O Development (M1 Kit Part)

IC670ALG310 Analog Output, Voltage, 8 Channel, +/-10V, 0 to 10V

IC697CPU782RR CPU, 16 MHz, 12K Discrete I/O, Expandable Memory, Floating Pt

IC800PSHV045 PSM-45HVi 45 kW high voltage power supply kit for Alpha servos

ControlLogix/1756 System 1756-OV32E 10-30 VDC ELEC FUSED SINKING OUTPUT 32 PT (36 PIN)

Industrial Computers 6182H-10KRH4D VVCE 1000, KEYPAD, STD MEM, ENET, DC

Process Control 1757-FIMEXP100 FOUNDATION FIELDBUS FIM MODULE EXPANSION

Operator Interface 2711P-RDB7C PV PLUS 700, KEY/TOUCH SCREEN DISPLAY MODULE

Support 9355-WABDER SUPT REINSTATEMENT CONTRACT FOR 9355WABDE

Support 9351-WESRTR SUPT REINSTATEMENT CONTRACT FOR 9351WESRT

ControlNet Products 1747-KFC15 SLC CNET SERIAL INTERFACE MODULE

RSI Software Products 9301-2SE2400ITE RSVIEW32 WORKS 32K (ITALIAN)

RSI Software Products 9355-WABOEMEU1R UPGRADE: OUT-SUPT: WINLINX TO RSLINX OEM CD

Motion Control MPL-A320P-HJ22AA MOTOR,SERVO,2.94NM,5000RPM,ENCDR,230V,4.0KG

Motion Control 2090-U3AE-D4409 CABLE,TWO AXISTO LOGIX 1756MOAE2 CARD,9M

CBL-119-1 Cable.SIMATIC T.I. 305 DCU (RS-422)