ABB GFD563A101 3BHE046836R0101ABB GFD563A101 3BHE046836R0101

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ABB  GFD563A101 3BHE046836R0101ABB  GFD563A101 3BHE046836R0101ABB  GFD563A101 3BHE046836R0101ABB  GFD563A101 3BHE046836R0101ABB  GFD563A101 3BHE046836R0101ABB  GFD563A101 3BHE046836R0101ABB  GFD563A101 3BHE046836R0101ABB

打开MCGS通用版组态软件，我们会看见5个部分，分别为主控窗口、设备窗口、用户窗口、实时数据库和运行策略。

 

首先我们先新建一个工程，将其命名为水泵控制系统并进行保存。

然后打开用户窗口完成相关图符的建立，老师在建工程时先建立了实时数据库，是因为对图符的控制属性有较清楚的认识，所以对于初学者来说，先画图符是最先的选择。

（1）在用户窗口中新建一个窗口0，并将其重命名水泵运行控制，在动画窗口中用标签建立动画的标题“水泵控制”

（2）绘制水泵

在软件中，已经为我们提供了“对象原件库”我们可以在其中选择所要的原件，所以接下来添加一个“泵30”图符再确定，可以调节图符的大小，以至达到美观的效果

（3）在泵下面添加两个“按钮”分别将名称改为“启动”和“停止”也可以双击来改变按钮的背景颜色。

（4）因为要展示停止和启动时的状态所以再添加两个指示灯，为了更为清楚的展现启动和停止的状态，也可以自己改造一个指示灯，其改造方法为先用一个库提供的指示灯作为改造对象先分解单元在将最前面的图符拖走，将底层的图符分解图符再改变其颜色和添加一个“可见度”属性并在表达式里填入@开关量，然后再对另一只指示灯做相关属性的设置。

（5）为了显示时间我们再添加两个按钮分别为“定时器启动”和“定时器复位”再添加 两个标签分别为控制“计时时间”和“时间到”。

（6)添加四个输入框将其属性设置为数值型，

（7）现在我们来进行实时数据库里相关数据的添加，分别为 水泵、启动、复位、定时器启动、定时器复位都是开关量，而“计时时间”和“时间到”为数值型。

(8)实时数据建立完成后，再进行用户窗口里图符的相关表达式的关联，由于要有时间控制所以在运行策略里我们要添加一个定时器，和一个脚本程序，在定时器属性里设置时间值为35秒，在脚本程序里用IF-THEN语句来编写控制程序。记住要用EXIT来划分步骤，在最后要进入运行环境测试前，应调节循环策略的属性，将定时循环时间改为200s。

任务二 水泵运行监控

前期仅是利用MCGS系统的“设备无关性”在水泵控制组态工程中借助定时器和脚本策略，初步实现了水泵控制系统的模拟运行，并未达到实时监控的目的，所以接下来要监控设置。

我们知道，水泵运行控制主要是使用PLC来控制的，而MCGS系统，一方面需要从PLC采集相关数据，改变实时数据库中对应变量的值，然后以画面中图符构件的动画形式显示出来，从而达到监视运行的目的；另一方面还需要将上位机组态环境中设置的暂停和运行时间写入PLC中，实现对水泵运行时间到调整，以及通过上位机启动和停止按钮实现对水泵硬件系统的运行和停止的控制。

打开前一个“任务一”将其另存为“水泵运行监控”在将“任务一”组态工程动画及属性设置进行改进。

（1）删除定时器策略及脚本程序策略。【在联机时，PLC完成控制任务，所以组态工程

中的定时器和脚本程序就无用了】

（2）修改数据库中与定时器相关的4个数据对象，分别为“定时器启动”“定时器复位”计时时间和时间到，以提高运行环境效率。然后在添加4个新的数据对象，分别为“运行时间显示”、“运行时间调整”、“暂停时间显示”和“暂停时间调整”，对象类型为数值型。

（3）在“动画组态水泵控制”窗口中删除与定时器相关的图符，并且制作6个新的文字标签。

（4）制作如图的动画窗口。

在设备窗口中添加一个“通用串口父设备”再添加一个“西门子_S7200PPI”。

（5）选择好后就对设备进行属性设置，以便与MCGS进行通信。

（6）在通用串口属性设置”串口端子号为“COM1”数据校验方式为“偶校验”采集数据为“同步采集”。最小采集周期设为200ms.【依据所接PLC型号进行设定】

（7）设置西门子PPI属性，添加4个i寄存器、2个Q寄存器、3个M寄存器和4个VW寄存器。

（8）在图纸上先画出PLC程序，注意为了较为正确的控制组态，所以在程序设计过程中要进行数据转换。加入转移指令和整数除法指令，将计时器时间除以10放到寄存器中。还要添加“上位机启动”和“上位机停止”。

（9）在联机监控操作时，打开MCGS时需要关闭Step7软件，然后进行通连道接，直到显示为0是就表示连接成功了，便可进行监控测试。

任务三机械手控制系统

机械手的运行控制较前两个任务还是增加了难度，

（1）首先我们先建一个工程将其命名为“机械手运行控制”再在用户窗口中新建一个窗口将其命名为“机械手控制”

（2）在用户窗口中建立所需的图符，

A.创建4个按钮，分别命名为启动、复位、定时器启动、定时器复位。

B.再用标签建立2个文本框分别命名为，计时时间、和时间到，和4个矩形框。

C.用矩形框建立机械手底座和用管道建立机械手横臂和竖臂，再用3个矩形建立抓手。

D.添加6个相同的步指示灯和2个启动和复位指示灯。其中6个步是下移、加紧、上移、左移、右移、放松。

E.关于要搬运的物块，当然自己要动手画出。用一个矩形和两个椭圆通过改变填充颜色和合成图符组成一个整体。

（3）在实时数据库里添加开关型数据分别为定时器启动、定时器复位、启动、复位、下移夹紧、上移、右移、放松和左移。左工件和右工件。

（4）再添加垂直移动量，水平移动量、计时时间和时间到等数据型数据。

（5）在各个图符里添加相关的属性，注意连接管子的两个矩形要合成图符因为要添加“水平移动量”属性。

（6）当相关属性在表达式里从实时策略里选完后，最后还要给机械臂添加大小变化的属性，其计算方法为臂伸长后的总长度=臂的实际长度+伸长的量，如何进行长度测量，先画一条直线打开查看栏里的状态条，便会在右下角显示长度，

（7）至于属性框里表达式的值则要通过下降的时间除以200ms

（8）在循环策略里添加脚本程序和定时器。

任务四 机械手运行监控

在任务二中已经介绍过监控的实际运用的意义，所以在此任务中就不再详细介绍。

（1）删除定时器策略及脚本程序策略。【在联机时，PLC完成控制任务，所以组态工程中的定时器和脚本程序就无用了】修改数据库中与定时器相关的4个数据对象，分别为“定时器启动”“定时器复位”计时时间和时间到，以提高运行环境效率。然后在添加4个新的数据对象，分别为“运行时间显示”、“运行时间调整”、“暂停时间显示”和“暂停时间调整”，对象类型为数值型。

（2）在“机械手运行控制”窗口中删除与定时器相关的图符，

（3)制作如图的动画窗口。

(4)在设备窗口中添加一个“通用串口父设备”再添加一个“西门子_S7200PPI”。

(5)选择好后就对设备进行属性设置，以便与MCGS进行通信。

(6)在通用串口属性设置”串口端子号为“COM1”数据校验方式为“偶校验”采集数据为“同步采集”。最小采集周期设为200ms.【依据所接PLC型号进行设定】

(7)设置西门子PPI属性，在基本属性里添加4个i寄存器、14个Q寄存器、6个M寄，其中M2.0为上位机启动，M2.1为上位机停止。

(8)在图纸上先画出PLC程序，注意为了较为正确的控制组态，所以在程序设计过程中要进行数据转换。加入转移指令和整数除法指令，将计时器时间除以10放到寄存器中。还要添加“上位机启动”和“上位机停止”。

(9)在联机监控操作时，打开MCGS时需要关闭Step7软件，然后进行通连道接，直到显示为0是就表示连接成功了，便可进行监控测试。

任务五 分炼机械手监控系统
 

 GFD563A101 3BHE046836R0101ABB  GFD563A101 3BHE046836R0101ABB  GFD563A101 3BHE046836R0101ABB  GFD563A101 3BHE046836R0101ABB  GFD563A101 3BHE046836R0101ABB  GFD563A101 3BHE046836R0101ABB  GFD563A101 3BHE046836R0101

Design content of PLC control system

(1) According to the design specification, the process analysis is carried out and the control scheme is determined, which is the basis of the design.

(2) Select input devices (such as buttons, switches, sensors, etc.) and output devices (such as relays, contactors, indicator lights and other actuators).

(3) Select the model of PLC (including model, capacity, I / O module and power supply, etc.).

(4) Allocate I / O points of PLC and draw I / O hardware wiring diagram of PLC.

(5) Program and debug.

(6) Design the operation console, electrical control cabinet, etc. of the control system and the installation wiring diagram.

(7) Prepare design instructions and operation instructions.

Labor shortage, talent shortage and high risk factor are common problems in the traditional construction industry. Production automation has become one of the reliable solutions at present. Robot automation can improve the safety, sustainability and cost-effectiveness of the industry. In the past year, abb has been committed to improving the production flexibility, efficiency and quality of the construction industry, and its application in the construction field has been continuously expanded. At present, a large number of innovative applications have been put into use. Programmable controller is an electronic system of digital operation, which is designed for application in industrial environment. It uses programmable memory to store instructions for executing logic operation, sequential control, timing, calculation and arithmetic operation, and controls various types of machinery or production processes through digital and analog input and output. PLC is the product of combination of microcomputer technology and traditional relay contact control technology. It overcomes the disadvantages of complex wiring, low reliability, high power consumption, poor universality and flexibility of mechanical contacts in relay contact control system, and makes full use of the advantages of microprocessor. The programmable controller is a non-contact device for the user, and the production process can be changed by changing the program. Therefore, the programmable controller can be selected in the preliminary design stage and the process can be determined in the implementation stage. On the other hand, from the perspective of manufacturers manufacturing programmable controllers, there is no need to specially design controllers according to the ordering requirements of users in the manufacturing stage, which is suitable for mass production. Because of these characteristics, the programmable controller was quickly welcomed by the industrial control industry after its appearance and developed rapidly. At present, programmable controller has become a powerful tool for factory automation and has been widely used.

The user can use the programmer to read the contents of the ram, and can also write the user program into the ram. Therefore, the ram is also called read / write memory. It is a volatile memory. After its power is disconnected, the stored information will be lost. Ram has high working speed, low price and easy rewriting. In order to save the user program and some data (such as the count value of the counter) in the RAM after the external power supply of the PLC is turned off, a lithium battery is provided for the ram. Some PLCs still use ram to store user programs. The lithium battery can be used for 2-5 years. When the lithium battery needs to be replaced, the "battery voltage is too low" led on the PLC panel will be on, and an internal flag bit will change to l state. Its normally open contact can be used to connect the indicator light or audible and visual alarm on the control panel to inform the user to replace the lithium battery in time. (2) Read only memory (ROM) the contents of the ROM can only be read, not written. It is non-volatile and can still save the stored contents after the power supply disappears. ROM is generally used to store the system program of PLC. According to the scanning principle of PLC ladder diagram program, scan sentence by sentence and execute the program in the sequence of left to right, top to bottom. When a program jump instruction is encountered, the jump address of the program is determined according to whether the jump condition is satisfied. When the user program involves the input / output state, the PLC reads out the corresponding input terminal state acquired in the previous stage from the input image register, reads out the corresponding image register from the output image register, performs logic operation according to the user program, and stores it in the relevant device register. We are committed to providing complete sets of electrical automation equipment and professional automation solutions for production lines. The company has successful experience in automation technology (especially in metallurgy industry and non-ferrous metal processing industry). We have cooperated with foreign parties for many times to complete the design, manufacture and commissioning of strip cold rolling, hot rolling and finishing equipment. The company also has successful experience in the transformation of old equipment. It makes reasonable use of the production gap of customers to complete the transformation and upgrading of old equipment, saving money for customers and ensuring normal production. For each device, the contents registered in the device image register will change with the program execution process. Supply chain transformation has opened a new era of real-time, end-to-end transparency and performance management. One of the keys to the development of this technology is RFID tags and readers, which help to automate the inventory process, simplify the workflow and speed up the operation of the production line. RFID solutions can also complement and integrate with emerging machine vision solutions to improve process accuracy and reliability. With the support of prediction analysis, the company can more accurately predict the future demand of parts or finished products at the weekly level. Normative analysis provides clear guidance on what actions can or should be taken now to protect the supply chain from relevant operational errors or potential destructive events.

This evolution of supply chain 4.0 is driven by significant advances in automation and traceability technologies. For example, RFID scanning technology updates the traditional two-dimensional barcode, improves productivity, and can be integrated with other solutions such as machine vision and predictive analysis. Fixed RFID readers will play an important role in the future warehouse environment. When combined with other advanced solutions, RFID technology can support the key economic drivers of warehouses or distribution centers, including asset visibility, productivity, quality control, tracking and traceability.

RFID technology has become more and more effective and cost-effective in the deployment of warehouse and logistics environment, making it more widely adopted. However, to achieve (ROI), we need to work with solution providers to help integrate technology into the business, so as to avoid isolated workflow and minimize complexity. Manufacturing plants are particularly suitable for the use of passive RFID readers because the materials there usually follow a fixed path through the facility. The new wide area advanced RFID antenna can expand the scanning range to track the real-time location of every asset in the warehouse.

In discrete manufacturing, inventory is usually serialized, and each unique part has a dedicated location. Using RFID tags, the production manager can ensure that the materials are correctly sequenced so that the correct components enter the production line at the right time.

Improving visibility not only enables organizations to detect errors after they occur, but also helps prevent problems from happening and avoid potential quality control problems that may damage the company's reputation or profits. In addition, preventing asset utilization problems and strengthening the tracking of raw materials can help enterprises maintain the operation of production lines without affecting productivity. Supply chain transformation is not limited to one or several industries. Most of the same supply chain technologies can be applied to multiple industries -- from automobiles and clothing to pharmaceuticals and groceries, from manufacturing plants and warehouses to transportation, and to final distribution points, such as retail stores and medical facilities. RFID solutions can help grocery stores, fast food stores, food suppliers and even hospitals significantly improve inventory visibility, reduce costs and reduce waste. Installing passive RFID readers in corridors such as porches or coolers can improve control capability and visibility without increasing labor costs. RFID can also improve the traceability of the drug supply chain and integrate with temperature monitoring solutions to provide more detailed information.

The frequency can be gradually increased by running under scalar to observe whether the current fluctuation is large. Storage requirements:

The storage of spare modules shall meet the following requirements: all modules must be packaged with anti-static bags or stored according to the requirements of the manufacturer. The temperature and humidity of the module storage room shall also meet the requirements of the manufacturer; Anti static measures shall be taken when accessing the modules. It is forbidden to touch the circuit board with hands at any time, and registration shall be carried out, and entry and exit procedures shall be handled.

(2) regular inspection

A small number of common spare parts kept by the discipline shall be inspected every six months. The inspection contents are as follows:

(1) The surface is clean, the printed board insert is free of oil, the printed board insert is free of oil, and there is no abnormality after slight knocking.

(2) The software loading and unloading test is normal, and the communication port and manual operation station work normally.

(3) Various analog and switching input and output channels work normally.

(4) Load the test software, and the normal operation shall not be less than 48h.

(5) Switching test of redundant modules.

(6) After the inspection, the inspection record shall be filled in and the conformity mark shall be affixed.

(3) inspection before use

Before the module is put into operation, check whether the communication ports, I / O functions and control algorithm functions meet the requirements; Check the module status on the engineer's station to meet the requirements; Install the configuration in the module and check whether it is correct.

(4) confirmation when put into use

When putting into use, the module address and other switches shall be set and confirmed by the supervisor before inserting the correct module position and filling in the record card.