基于PLC的柔性自动化生产线系统研究与设计

【作者】 杨磊；

【导师】 蔡彬；

【作者基本信息】 曲阜师范大学 ， 系统工程， 2010， 硕士

【摘要】 近年来,随着经济的发展和社会的进步,对柔性自动化的研究越来越受到人们的重视。使用柔性自动化生产线、提高生产线的柔性化程度已经成为当今制造业适应市场需求、加速产品更新换代的一种主要手段。工业发达国家在柔性自动化技术的研究中大多以提高系统整体可靠性、实用性为重点,注重对单元技术的开发,在柔性自动化诸多领域取得了很大的成就。而我国对柔性自动化技术的研究与国际先进水平相比还存在不小的差距,难以满足国内需求,因此,柔性自动化技术的研究及普及迫在眉睫。本文在对柔性自动化理论研究的基础上,阐述了建立一条模拟柔性自动化生产线系统的整个过程,采用可编程控制器(PLC)、WinCC组态软件及现场总线等技术,实现了对系统的过程控制、过程监测：(1)采用PLC作为控制系统控制器。控制系统是柔性自动化生产线的核心部分,为了达到控制要求,实现整个系统的柔性控制,本文利用PLC强大的数据处理和数值运算功能,将具体的工艺用PLC程序来实现。通过调试及仿真,证实本文所编控制程序准确有效。(2)将条码扫描枪纳入到所设计的模拟柔性自动化生产线系统中来,不仅节约了判断工件类型所需要的多种传感器,而且在系统工件类型改变或者扩展系统时仅需修改系统内部程序即可,硬件部分改动较小,与传统的教学实训装置相比将具有相当的优势。(3)研究了利用WinCC组态软件完成了数据归档、报警记录、上位机与PLC通信及生产过程动态显示等功能。(4)提出了一种利用Excel数据表对系统内部的工件信息进行管理的方案,不仅节约了PLC的存储空间,而且便于管理,可以对数据进行灵活控制,改变加工对象时仅需修改数据表即可。(5)在通讯功能的实现上,采用PROFIBUS-DP网络对整个系统进行组网设计,采用上位机作为DP主站,三台S7-200 PLC作为DP从站的方式。上位机与下位控制器之间实现了传输率为1.5Mbps的现场总线通信,可以圆满完成通信任务。更多还原

【Abstract】 In recent years, more and more attention has been paid at the research on Flexible Automation with economic development and social progress. It has become a major means for the manufacturing industry to adapt to market demand and accelerate product upgrading. Westen developed countries use automatic production line in order to enhance the system reliability. They have made great achievements in Flexible Automation. There is still a greet gap between China and the international advanced level, and it can’t meet domestic demand, so it’s extremely urgent to research and popularize Flexible Automation technology.On the basis of theoretical studies in Flexible Automation, this paper described the whole process to establish a system of flexible automated production line. Programmable Logic Controller (PLC), WinCC configuration software and field bus technology were used to achieve the process control and process monitoring.(1) PLC was used as system controller. Flexible automation control system is a core part of the production line. In order to achieve the control requirements and comply the flexible control of the entire system, PLC’s powerful data processing and number computation function was used to achieve the specific process control. It’s proved that this control program act accurate and effective through the debugging and simulation.(2) The code scanner was incorporated into the flexible automated production line system, that can not only save sensors which used to judge type of the workpiece. Besides, only the system software modified when the types of workpiece in the system are changed or the system is extended. Small changes in hardware. Compared to traditional teaching equipment this system would have a considerable advantage.(3) WinCC configuration software was used to complete functions such as data archiving, alarm records, communication between PC and PLC and process dynamic display.(4)Proposed a solution using Excel data tables to manage workpiece information, which not only saves storage space in PLC, but also let the system more manageable. Only the data of object table was modified when the processing object changed.(5) To realize the communication between PC and PLC, PROFIBUS-DP network was used to complete the whole network system design. PC was used as DP master, and three S7-200 PLC were used as DP slaves. The field bus commnication was realized between PC and PLC at 1.5Mbps.更多还原