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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：

　?、倌７罗k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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Motion Control MPG-A010-031S24 MOTOR,SERVO,GEAR RATIO 31,26NM,157RPM,SINGL,BRK

Silver Series 1770-HT8 HART 8 CHANNEL NON-ISOLATED TERMINAL BLOCK

HE693OIU197 Compact VF Fenius OIU w/numeric keypad, powered by 24VDC

IC660BBR101 Block Relay Output Normally Open 16 Circuits

QPI3D200S2P QUICKPANEL COLOR 10.5" STN

ST-5211 STXi Serial Interface module RS-232C, 1 Channel

20BC1P3A0AYNANA0 PowerFlex 700 AC Drive 20B

20F1AGD361AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-A2P3N104 PowerFlex 40- 0.4 kW (0.5 HP) AC Drive

140DDI35300 Quantum 開關(guān)量 DC 輸入, 32點(diǎn), 24 VDC, 4組隔離

284D-FVD4P0B-10-CR-DB-SB DeviceNet Variable Frequency Drive

E3JM-DS70M4 70cm,擴(kuò)散反射式,觸點(diǎn)輸出3A 電源:24-240V AC/DC

1492-SJ8-10 IEC Term Blck 10 pole Side Jumper

人機(jī)界面 6AV6542-0BB15-2AX0 OP170B 操作員面板，5.7 英寸，藍(lán)色

6ES78331FC020YA5

1497B-A13-M11-0-N Control Power Transber

1606-XLS240F AC or DC Input 48 to 56VDC Out 240W PS

1769-CRR1 CMPLX 0.3 m Right to Right Bus Exp Cable

188-K4D400 Miniature Circuit Breaker 40 A

194R-D630-1753 Disconnect, Fused, Din-Type, 630 A

2090-CPBM7DF-12AA07 MP-Series 7m Power and Brake Cable

2090-XXNPMP-16S04 MP-Series 4 m Length Power Cable

CBL-15-MP-30 Power cable for MTR-1N splashproof stepping motors. 30 feet

GF-0196/OBG Connecting FlashCable to Brown & Sharpe Digit Dial plus (Owens Brockwa y OEM).

IC200TBX114 Tool box, 14 point (IC200UDR001) 24VDCIn/Relay Out, AC Powered (requires AC power), V ersaMax DataPanel DP45 (requires 24VDC supply) with Programming software and cables, (IC640VPS 00, IC752DDZ000, IC200CBL555, IC646MPM001)

IC646TBSPMPS100 Smart Process Monitoring Process+ server 100 loops

IC647NRP000 CIMPLICITY HMI Recipes Option

IC693ACC319 Spare Parts Kit (I/O, CPU, PCM)

IC752BDT000RR Datapanel 240T, 240x128 LCD with CCFT backlight. 6x8 Matrix Resistive touch screen with text, bitmaps, bar graphs, real time clock.

IC800VMCE1200 Encoder cable for 1 kW to 3 kW VersaMotion servo motors- 20 meter

SLC/1746 System 1746-OV16 DC OUTPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6189V-1ACPS AC POWER SUPPLY 1U STANDARD

Application-specific products 6556-SPLS PROGRAMMABLE LIMIT SWITCH SOFTWARE FOR THE SLC

Operator Interface 2711-B6C16L1 PV600 COLOR KEY&TOUCH, DF1 & RS232 PRINT

Support 9301-2SE2300ZHR SUPT REINSTATEMENT CONTRACT FOR 93012SE2300ZH

Support 9307-EM643PXS SUPT RENEWAL CONTRACT FOR 9307EM643PXENE

DeviceNet Products 1734D-IB16S 24 VDC 16 IN, DNET COMMS, SPRING

RSI Software Products 9301-2SE250PTU1R RSVIEW32 WORKS 32K-100K UPGRADE OUT-SUPT (PT)

RSI Software Products 9358-BNT30UB1R UPGRADE: OUT-SUPT: RSBATCH 30 UNITS TO BUNDLE

Motion Control MPL-B320P-SK22AA MOTOR,SERVO,2.94 NM,5000RPM,SINGL,460V

Motion Control 2090-MPPC-S KIT CONNECTOR,POWER STRAIGHT MF

GFK-0585 Series 90 PLC SNP Communication's Driver Reference Manual

IC641VPS950 VersaPro Standard Edition 50 Seat Site License - Windows Programming Software for Series 90-30 and VersaMax PLCs

MSCPU-21280698 Marathon Std CPU - 333 MHz AMD CPU, 128M, 6G, Win98, no expansion slots

PSPC-DC5/E-220L Prof Shop Floor SPC DC 5 User eSig 220v

20BC015A0AYNANC0 PowerFlex 700 AC Drive 20B

20F11FC015JA0NNNNN PowerFlex 753 AC Packaged Drive

2198-KITCON-CAP1300 CONKIT,K5500,CAP MODULE

2711P-RBB10 PanelView Plus Accessory

280-PWRM35H-M20 ArmorConnect 3-PH Power Media trnk cable

CQM1-PR001-E 編程器?（配1.5米連接電纜）如需連CQM1H系列CPU,需加CS1W-CN114

1492-N22 TERM BLCK Rigid MTG Rail

通訊處理器CP 6GK7 343-1EX21-0XE0 "CP343-1 工 業(yè) 以 太 網(wǎng) 通 訊 處 理 器10/100Mbit/s,RJ45 接口"

行程開關(guān) 3SE53222SE22

TIA 博途 WinCC 選件 6AV2107-0KP00-0BB0 SIMATIC WinCC WebNavigator for Runtime Professional 150 Clients

1585J-M8HBJM-2M5 RJ45 Ethernet Media

1760-DUB PicoGFX with Keypad Display

188-K2B200 Miniature Circuit Breaker 20 A

194E-Y80-1753-6N 80 A 194E Load switch

2090-CHBP8S8-12AA02 Kinetix 6000M IDM Hybrid Cable

2090-UXPC-D0909 Ultra Series 9m Interface Cable

BC647MODEV Motion Developer for S2K Series Amplifiers/Controllers with Proficy GlobalCare Complete with USB Hardware key

GC647IFPRRNUNLMT GCC iFIX Profsnl SCADA Unlmt Run

IC200CHS014 I/O interposing box style Thermocouple cold junction compensation

IC646MRA300 View Runtime 300 I/O

IC647IFSTDV00900M iFIX Standard HMI 900 I/O Development (M4 Part)

IC670CBL002 21 inch I/O Expansion Cable

IC697CPX935 CPU, 96 MHz, 12K Discrete I/O, 1M byte fixed user memory

IC800SKCEZ050 Encoder cable to connect an S2K to any 30 Watt to 750 Watt S-series servo motor. 5 meters

ControlLogix/1756 System 1756-IT6I2 ENHANCED ISOL THERMOCOUPLE/MV INPUT 6PTS (20 PIN)

Industrial Computers 6182H-10TRH15D VVCE 1000, TOUCH, STD MEM, CNET, DC

Process Control 1757-FIMUPG010 FIELDBUS LICENSE UPGRADE, 10 FIMS

Operator Interface 2711P-RGK15 PV PLUS/VVCE PROTECTIVE ANTIGLARE OVERLAYS QTY 3

Support 9355-WABITR SUPT REINSTATEMENT CONTRACT FOR 9355WABIT

Support 9354-LN100S 9354-LN100 SOFTWARE SUPPORT CONTRACT RENEWAL

ControlNet Products 1784-PCIC CONTROLNET PCI BUS MESSAGING CARD WITH

RSI Software Products 9301-2SE2400KOE RSVIEW32 WORKS 32K (KOREAN)

RSI Software Products 9355-WABSNEU1 UPGRADE: IN-SUPT: RSLINX SINGLE NODE TO RSLINX OEM

Motion Control MPL-A320P-SK22AA MOTOR,SERVO,2.94 NM,5000RPM,SINGL,230V,4.1KG