PLC Simulation Control of Assembly Line

Transcription

1 Computer Simulation In Application Original Research Article PLC Simulation Control of Assembly Line Qianming Wu,Zhongyuan Xu,Zhili Han Electronic Information Engineering College, Jinhua University of Technology, Zhejiang, China ABSTRACT This paper mainly introduces the application of PLC simulation control in industrial production, and requires the use of configuration software and PLC (SIMEINS S7-200) control system connection, the use of lower computer implementation, the host computer monitoring method to build complete assembly line simulation control system. Through the PLC simulation control and configuration monitoring, this paper implements the assembly line control and monitoring. KEYWORDS: PLC control; lower computer implementation; host computer monitoring; configuration monitoring 1. Introduction 1.1. Information about PLC Programmable logic Controller (PLC) is a programmable logic controller, a digital operation of the electronic system, designed for industrial applications in the design. It uses a class of programmable memory for its internal storage of programs, the implementation of logical operations, sequential control, timing, counting and arithmetic operations and other user-oriented instructions, and through digital or analog input and output control of various types of machinery or the production process, is the core of industrial control PLC, programmable controller. Another PLC also has the following names: Power Line Communication and power line communication. Programmable Controller is a member of the computer family, is designed for industrial control applications. Early programmable controller called PLC, which is mainly used to replace the relay logic control. With the development of technology, the function of this device has greatly exceeded the scope of logic control, therefore, today this device is called programmable controller, referred to as PC. But in order to avoid confusion with the personal computer, so the programmable controller referred to as PLC, plc since 1966, the United States, Japan, and Germany, programmable controller quality and powerful. In the industrial automation production, because PLC control has a series of advantages, and easy to control, by the enterprise's favorite, while the use of configuration software to monitor the production process, but also to make the whole process becomes visual. And the Industrial Automation Universal Configuration Software - Kingview software system is independent of the specific PLC or field components used by the final engineering staff. For different hardware facilities, simply configure the corresponding communication driver for the configuration. The configuration king supports a range of hardware devices, including programmable controllers (PLCs), intelligent modules, boards, smart meters, frequency converters, and so on. So the assembly line in the PLC simulation control the use of more and more widely Experimental objectives and specific requirements A. Experimental purpose Learn to use the configuration software and PLC (recommended SIMEINS S7-200) control system connection, the use of the next machine implementation, the host computer monitoring method to build the assembly line to complete the simulation control system. B. Experimental devices and accessories (1) TKPLC-1 type experimental device Copyright This is an Open Access article distributed under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License ( permitting all non-commercial use, distribution, and reproduction in any medium, provided the original work is properly cited. 13

2 PLC Simulation Control of Assembly Line (2) Installed STEP7-Micro / WIN32 programming software and configuration King software a computer (3) PC / PPI programming cable one (4) A number of connecting wires. A, H, E, F, G, and H jacks in the lower frame are connected to the output points Q0.0 of the main unit, respectively., Q0.1, Q0.2, Q0.3, Q0.4, Q0.5, Q0.6, Q0.7. Start, shift and reset jacks are connected to the host input points 10.0, 10.1, and There are 16 stations in the conveyor belt. The work-piece is loaded from No. 1, and three assembly operations are carried out in three stations (A) (Operation 1), B (Operation 2) and C (Operation 3) respectively. After the last station and then into the warehouse; other stations are used to transfer the work-piece. 2. PLC control system and configuration software and introduction 2.1. PLC control system Basic introduction PLC refers to the computer technology based on the new industrial control device. It is a digital operation of the electronic system, designed for industrial applications in the design. It uses a class of programmable memory for its internal storage procedures, the implementation of logical operations, sequential control, timing, counting and arithmetic operations and other user-oriented instructions, and through digital or analog input / output control of various types of machinery or the production process. PLC is a programmable logic circuit, but also a very close combination of hardware and language, in the semiconductor has a very important application, it can be said that there are semiconductor where there is PLC. B. PLC function (1) Logic control (2) Timing control (3) Count control (4) Step (sequential) control (5) PID control (6) Data control: PLC with data processing capabilities. (7) Communication and networking (8) Other: PLC also has many special function modules, suitable for a variety of special control requirements, such as: positioning control module, CRT module. C PLC features (1) High reliability, anti-interference ability High reliability is a key feature of electrical control equipment. PLC due to the use of modern large-scale integrated circuit technology, the use of strict manufacturing process, the internal circuit to take the advanced anti-jamming technology, with high reliability. For example, Mitsubishi's F-series PLCs produce an average of 300,000 hours without downtime. Some PLCs that use redundant CPUs have an average trouble-free working time that is longer. PLC from the machine outside the circuit, the use of PLC constitute a control system, and the same size relay contactor system, electrical wiring and switch contacts have been reduced to hundreds or even thousands of times, the failure will be greatly reduced. In addition, PLC with hardware failure self-detection function, failure can be issued in time alarm information. In the application software, the application can also be programmed into the peripheral device fault self-diagnosis program, so that the system in addition to PLC other than the circuit and equipment also get fault self-diagnostic protection. In this way, the whole system has a very high reliability. (2) Complete supporting, functional, strong applicability PLC development to today, has formed a large, medium and small series of various products. Can be used for industrial control of various sizes. In addition to the logic processing functions, modern PLC most of the data with the perfect computing power, can be used for a variety of digital control. PLC in recent years, a large number of functional units, so that PLC penetration to the position control, temperature control, CNC and other industrial control. With the 14

3 Qianming Wu, et al PLC communication capabilities and human-computer interface technology development, the use of PLC to form a variety of control systems become very easy. (3) Easy to learn and use, welcomed by engineering and technical personnel PLC as a general industrial control computer, is for industrial and mining enterprises of industrial equipment. It is easy to interface, the programming language is easy for engineering and technical personnel to accept. The graphical symbols of the ladder language are quite close to the expression and the relay circuit diagram. The function of the relay circuit can be easily realized by using only a small amount of logic control commands of the PLC. For those who are not familiar with electronic circuits, people who do not understand the computer principles and assembly language use computers to engage in industrial control to open the door. (4) The system design, construction workload is small, easy maintenance, easy to transform PLC with the storage logic instead of wiring logic, greatly reducing the control equipment outside the wiring, so that the control system design and construction cycle is greatly shortened, while maintenance has become easy. It is more important to make the same equipment change the process to change the production process possible. This is suitable for multi-species, small batch production occasions. (5) Small size, light weight, low energy consumption To ultra-small PLC, for example, the newly produced varieties of the bottom of the size of less than 100mm, the weight of less than 150g, power consumption only a few watts. As the small size is easy to fit into the mechanical interior, is to achieve the ideal mechanical and electrical integration control equipment. D PLC control system design basic principles (1) To meet the maximum control of the controlled object requirements. (2) To meet the control requirements under the premise of trying to make the control system simple, economical, easy to use and maintain. (3) To ensure that the control system is safe and reliable. (4) Taking into account the development of production and process improvement in the choice of PLC capacity should be appropriate margin Configuration software Basic introduction Configuration development monitoring system software is a new type of industrial automatic control system is a standard industrial computer software and hardware platform integrated system to replace the traditional closed system, it has a strong adaptability, open, easy to expand, economic, development short cycle and other advantages. Usually this system can be divided into control layer, monitoring layer, management three levels. The monitoring layer is connected to the control layer, on the connection management layer, which not only realizes the real-time monitoring and control of the scene, and in the automatic control system to complete the upload and release, the important role of configuration development. Especially consider three aspects: picture, data, and animation. Through the monitoring system requirements and the realization of the function of the analysis, the use of configuration to monitor the system design. The configuration software also provides a visual monitoring screen for the experimenter, which facilitates realtime monitoring of the tester. Moreover, it can make full use of windows graphics editing functions, easy to form a monitoring screen, and animation to display the status of control equipment, with alarm windows, real-time trend curve, can facilitate the generation of various reports. It also has a wealth of device drivers and flexible configuration methods, data link functionality. B. Specific functions (1) Visual operation interface, true color display graphics, support progressive color, rich library, animation connection. (2) Unparalleled power and flexibility, with full scripting and graphics animation capabilities. (3) You can save a portion of the picture for later analysis or printing. (4) Variable import and export functions, variables can be exported to the Excel table, the convenience of the variable name and other attributes to modify, and then into the new project, to achieve the secondary use of variables, saving development time. (5) A strong distributed alarm, event handling, and support real-time, historical data distributed save. 15

4 PLC Simulation Control of Assembly Line (6) Powerful scripting language processing that can help you achieve complex logical operations and decision processing. (7) The new WebServer architecture, full support for picture publishing, real-time data release, historical data release and database data release. (8) Convenient recipe handling function, rich equipment support library. C. Use configuration to achieve control simulation A. Basic method: (1) Graphical interface design (2) Construct the database (3) To create an animation connection (4) Operation and debugging B. Configuration features: (1) The experiment with all the software to achieve, just use the existing computer can complete the automatic control system course experiments, thus greatly reducing the purchase of equipment funding. (2) The system is a Chinese interface, with a man-machine interface friendly, the results of the advantages of visualization. For the user, the operation is simple and easy to learn and simple programming, parameter input and modify the flexible, with multiple or repetitive simulation of the control operation, real-time display parameters before and after the system characteristics of the curve, can be very intuitive display control system real-time trend curve, these strong interaction ability in the automatic control system experiment can play the desired effect. C. Support for multimedia (1) Configuration can be embedded in the picture (2) Can play sound files (3) Play the animation (4) Support video capture equipment D configuration control process to consider the following three aspects (1) Graphics, how to use the abstract graphics to simulate the actual industrial site and the corresponding industrial equipment. (2) Data, is to create a specific database, and use the variables in the database to describe the various properties of industrial objects, such as water level, traffic and so on. (3) Connection is what kind of animation on the screen to simulate the operation of field devices, and how to let the operator input control equipment instructions. 3. Text 3.1. Procedure ladder diagram 16

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7 Qianming Wu, et al 3.2. PLC program (STL statement) LD 10.2 R Q0.0, 8; System reset LBL 1; program loop LD 10.0; Operation D runs for 1s AN M5.0 S Q0.3, 1 TON T37, 10 LD T37; operation D is stopped S M5.0, 1 LD T37; Operation A runs automatically for 2s O Q0.0 A 10.0 AN M5.1 S Q0.0, 1 R Q0.3, 1 TON T38, 20 LD T38; operation A stops S M5.1, 1 LD T38; press the shift button to operate E to run O M0.3 S M0.3, 1 LD I0.1 A M0.3 O Q0.4 AN M5.2 19

8 PLC Simulation Control of Assembly Line S Q0.4, 1 R Q0.0, 1 TON T39, 10 LD T39; Operation E Run 1s Stop S M5.2, 1 LD T39; automatic operation after operation B1s 2s O Q0.1 AN M5.3 S Q0.1, 1 R Q0.4, 1 TON T40, 20 R M0.3, 1 LD T40; Operation B stops S M5.3, 1 LD T40; press the shift button to operate F for 1s O M0.4 20

9 Qianming Wu, et al S M0.4, 1 LD I0.1 A M0.4 O Q0.5 AN M5.4 S Q0.5, 1 R Q0.1, 1 TON T41, 10 LD T41; operation F stops S M5.4, 1 LD T41; Operation C runs for 2s O Q0.2 AN M5.5 S Q0.2, 1 R Q0.5, 1 TON T42, 20 R M0.4, 1 LD T42; Operation C stops O M0.5 S M0.5, 1 S M5.5, 1 LD I0.1; Press the shift button to operate G for 1s A M0.5 O Q0.6 AN M5.6 S Q0.6, 1 R Q0.2, 1 TON T43, 10 LD T43; operation G is stopped S M5.6, 1 LD T43; press the shift button, operation H run 2s O Q0.7 AN M5.7 21

10 PLC Simulation Control of Assembly Line S Q0.7, 1 R Q0.6, 1 TON T44, 20 LD T44; Operation H stops S M5.7, 1 LD T44 R M5.0, 8; register reset LD T44 JMP 1; Jump to the beginning of the loop 3.3. Configuring the monitoring program A configuration monitor screen B Defines the connection of the variables in the configuration to the PLC C configuration and equipment PLC connection D. Configure the monitoring program If (\\\\ this site \\ operation D \\\\ this site \\ operation E \\\\ this site \\ operation F \\\\ this site \\ operation G == 1) { \\\\ this site \\ move = \\\\ this site \\ shift +2; } Else { \\\\ this site \\ move = \\\\ this site \\ move; } This procedure means that when the operation of the DEFG operation, the conveyor belt running a distance, when the operation ABC running, the conveyor belt to stop running, guide the action is completed, the conveyor belt to continue to work. 4. Conclusion I learned about more PLC and configuration of the relevant knowledge, but also improve the practical ability and develop courage to bear hard, diligent thinking habits. We have been on the PLC before the course, may be learned when the master is not very good, but also forget the knowledge of learning almost. But for this experiment, I have not grasp the knowledge of the past as much as possible, do not understand also asked the teacher. Probably because of the destination to learn it! I also understand and master the knowledge of programmable control more deeply. In addition, the beginning of the experiment, I do not understand the configuration software, but I understand the relevant information through the Internet, I also have a relatively deep understanding and understanding of the configuration in the industrial control of the specific function, as well as its production process of visual control and monitoring. And through the configuration software I can better learn and apply PLC programmer, so I learn more thoroughly and comprehensive. Always used to think about themselves, their own solution, perhaps some problems can be resolved, but after all, they think, has some limitations. In this experiment, under the guidance of the teacher and I together with the students, complement each other short, play their strengths, together come up with a lot of ways to solve the problem, and we remind each other, encourage each other, for the other wrong, make up the other side of the defect, so the cooperation together than a person to do more ideas, more efficient, but also make our program more refined, more perfect, functional completion is also better. There is a saying that the team is good. And in the past, I feel that the original experiment itself is not so boring, as long as you are willing to invest, it is very have to study and challenge. 22

11 Qianming Wu, et al During this time I exercise their own will, in the face of difficulties do not retreat, I believe that I believe everything will be resolved, as long as I am willing to take the time to see the information, earnestly pondering, ask others, there is no problem cannot be solved. However, I think it is more important that we have to develop a habit of thinking. In the course of the experiment, we need to constantly modify and improve, which makes us aware of the importance of careful. The experimental process will be my permanent memory. But also very grateful to the teacher can give me such a chance, let me learn a lot of books do not have things, but also let me see their own deficiencies can be improved. References 1. The principle and application of programmable logic controller - Machinery Industry Press [Wu Zhongjun, Huang Yonghong, editor] 2. Industrial control configuration software - Electronic Industry Press [Wang Zhifeng, editor] 3. Configuration software control technology - Northern Jiaotong University Press [Zhang Wenming, Liu Zhijun, editor] 4. PLC application development technology and engineering practice People s Posts and Telecommunications Press 5. PLC application technology - Maetcchinery Industry Press [Liao Changchu, editor] 23