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本文介绍了西门子 S7-200 SMART PLC、SMART LINE 触摸屏以及 SINAMICS V20 变频器在套标机上的应用，阐述了设备工艺流程、控制系统的配置选型、软件设计和实现的功能。经测试，该方案能完全满足高速套标机的各项技术要求，运行稳定，性能良好。
　　关键词：S7-200 SMART SMART LINE SINAMICS V20 套标机
1 引言
　　套标机是一种将热缩塑胶商标桶卷自动切断，准确套入容器的包装机械，配合后热收缩工序，将标签完好地固定于容器适当位置。
　　上世纪 90 年代以来，我国的快速消费品包装工业得到了迅速发展，快速消费品企业的生产集中度和自动化程度在不断提高，包装设备在向大型化、快速化、高效化、自动化方向发展。套标机作为后段包装技术含量较高的设备之一，其优良的高速稳定性能，独特的灵巧化设计，人机协和的安全模式，得到了广大客户的充分肯定。套标机的使用大大降低了套标环节的人力物力，现已广泛应用于啤酒饮料、化工、医药等行业。
2 套标机工艺原理
　　2.1 套标机结构
　　从工艺功能的角度进行划分，套标机的结构可分成以下 9 单元。并如图 1 所示。
　　(1) 供料组：由变频器带动供料电机旋转，用以传送标签膜料;
　　(2) 电眼架组：使用光纤电眼传送信号，提供下标伺服做定尺寸输送，电眼位置可高低调整;
　　(3) 驱动组：采用双驱送料机构，由下标伺服电机驱动。用于固定中心柱和下标动力传动;
　　(4) 刀盘组：采用同步轮机构，由伺服电机驱动，当进瓶光电 7 给出信号时，切刀电机带动刀片旋转一周将标签切断;
　　(5) 刷下组：采用同步调整机构，将刷下两组传送轮调整至中心柱下方与滚轮轻微接触，待标签通过时以较高转速将标签套入瓶子;
　　(6) 分瓶螺杆：将欲套标瓶做等距分开，进入带瓶组，速度由变频器控制，与输送带同步;
　　(7) 照瓶电眼：检测是否有瓶子通过，当有瓶子经过时输出讯号使切刀开始旋转，左右位置可以调整;
　　(8) 输送带：使用变频器调整输送带速度，以适用于各产能的速度匹配;
　　(9) 带瓶组：采用两侧同步传动，标签高低与夹瓶定位各一只手轮调整，目的使瓶子输送时不摇晃和控制套标签高度，速度由变频器控制，与输送带同步。
　　2.2 套标机工艺流程
　　当输送带上有瓶子经过照瓶电眼时，由伺服控制的切标电机会将标签切断，切标完成后下标伺服电机开始动作，等到光纤信号到来时停止送标，同时刷下料轮会将已经切断的标签刷下套入瓶子上，完成一次动作。具体工艺流程如图 2 所示。
硬件系统设计
　　3.1 硬件系统分析
　　本系统需要两路高速脉冲输出，分别控制切刀和下料伺服;一路高速计数器，用于控制切刀停止的位置，切刀停止位置应不影响下标的动作，否则会造成堵标。
　　以往套标机的调速方式普遍采用电位器控制，用三个电位器分别控制输送带电机，定位皮带电机和螺杆电机，供料电机的速度因为不经常调节，所以用变频器本身自带的电位器调速。每次输送带速度变更时，都需要重新调节螺杆和定位皮带的速度。调节时主要依靠调试人员的技术经验和不断的放瓶测试，才能使其线速度基本同步。本项目中设备的 I/O 清单如表 1 所示。
　　3.2 硬件系统设计
　　在本项目的电控方案中，选用西门子 SMART 解决方案，包括 S7-200 SMART PLC、SMART LINE 触摸屏和 SINAMICS V20 变频器。根据上述 I/O 需求，总共 12DI/12DO，选用 CPU ST40(24DI/16DO) 即可满足需求。 SINAMICS V20 变频器通过 USS 协议与 PLC 进行通讯，不仅控制更加方便，也节省了 PLC 的 I/O 点。通过计算可将电机角速度转化为输送带线速度。PLC 和触摸屏通过以太网进行通讯，只需要在触摸屏上输入生产速度，其他电机将会自动进行线速度同步。该方案大大缩短调试时间，降低调试难度。硬件结构如图 3 所示，主要硬件配置表如表 2 所示。
4 软件系统设计
　　4.1 运动控制配置
　　S7-200 SMART 集成了三路 100kHz 的高速脉冲输出，在本系统中切刀伺服占用 Q0.0，下标伺服占用 Q0.1。打开 Micro/WIN SMART 集成的运动控制向导，配置轴 1 和轴 2，选择单向相对脉冲，最大速度 50K，最小速度 1K，加减速时间 30ms，然后生成子程序。
　　4.2 高速计数配置
　　S7-200 SMART 集成了 4 路高速计数器，在本系统中只使用了高速计数器 HSC0，用于接收切刀的脉冲输出，占用输入点 I0.0。打开 Micro/WIN SMART 集成的 HSC 向导，配置 HSC0，选择工作模式 0，预设值为 80000，当前值为 0，计数方向向上，勾选 PV=CV 时中断，步数 1，然后生成。当切刀伺服启动后检测到刀盘原点光电时，利用外部中断快速更新高速计数器 HSC0 的当前值和目标值，目标值等于当前值加上偏置值。PV=CV 中断时停止脉冲输出，同时启动下标伺服。
　　4.3 USS 通讯
　　S7-200 SMART 自带库文件 USS 协议，只需调用 USS 功能块即可实现 PLC 与西门子变频器的通讯。通过 USS_INIT 进行通讯参数初始化设置，包括与变频器通讯的波特率，激活的变频器个数，所占用的端口等，通信参数必须与变频器设置的一致，否则无法通讯。每次通信参数的更改都需要重新执行此命令，本项目中的通讯参数固定，所以只上电执行一次。通过调用 USS_ CTRL 指令可以直接控制变频器的启动、停止以及频率，每条 USS_CTRL 指令只能控制一台变频器。
　　4.4 SINAMICS V20 变频器的配置
　　设置V20变频器的连接宏为Cn010—USS控制，分别设置螺杆、皮带、供料、输送带变频器地址 P2011[0] 为 1、2、3、4。同时，设置应用宏为 AP030—传送带控制，SINAMICS V20 可自动配置适合传送带应用的控制参数。
 

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IC693PTM100CA Conformal Coated Power Transducer Module

IC756MDV001J-97 DV Development - Alpha OpenVMS Addt'l User, Japanese, Version 9.7

MicroLogix 1000/1761 System 1761-NET-DNI DEVICENET INTERFACE (DNI)

PLC-5/1771 System 1771-NBTC HIGH RESOLUTION ISOLATED ANALOG MODULE

Distributed I/O 1792D-CB18 MAXUM ROUND MEDIA 18MM BASE, PASSTHRU FOR DNET

Communications 9351-HPUS INTERCHANGE FOR HP-UX

Operator Interface D6190-6.5.24 CONTROLVIEW GETTING STARTED

Support 9356-STD2400S SUPT RENEWAL CONTRACT FOR 9356STD2400

Support 9392-CDRSFRE DATADISC ENGLISH/FRENCH BUNDLE

RSI Software Products 9323-L2300DU UPGRADE: IN-SUPT: 6200-2 BOTH TO AI-2 BOTH

RSI Software Products 9301-2SE3500KOU5 RSVIEW32 RUNTIME 5K-100K UPGRADE IN-SUPT (KO)

RSI Software Products 9356-SQLSAPADENE RSSQL FOR SAP SOLUTIONS ADDITIONAL SAP MODULE

Motion Control TL-A230P-BJ32AA MOTOR, SERVO, 1.3NM, 5000RPM, 17BIT SERIAL FEEDBAC

44A738935-001 Cable, Motion Mate MCS300 Series Interface Cable

IC200CHS002 I/O CARRIER BOX STYLE

IC694MDL340 OUTPUT MODULE 120 VAC 0.5AMPS 16 POINTS

MSI-UNIV-WEB-25 Universal Web Client(RTIP / Dashboard / Web / Excel Addin) 25 Pak

VSPC32-OPC50 OPC Client Option includes VisualSPC Importer (licensing is per client PC), Support for 26 to 50 Points/Tags.

20BD040A0AYNANC0 PowerFlex 700 AC Drive 40 A at 30 Hp 20B

20G11JC1K1JN0NNNNN PowerFlex 755 AC Packaged Drive

22D-D010N104 PowerFlex 40P- 4 kW (5 HP) AC Drive

140NOE77101 Quantum TSX QUANTUM ETHERNET 10/100 BASE T100FX

290D-FBZ-G2 Direct Online Starter

E53-AZ01 NEW RS232通讯板

1761-NET-DNI DeviceNet 网络接口模块

PXIe-2569

AVCLAN PS10311 PC113-A

C79298-A3238-B903

MIO-AUDIO 888

D1280E1-PCI

Q80BD-J71LP21-25

1492-N901 TERM BLCK Marking Cards for HM

安装导轨 6ES7390-1AJ30-0AA0 安装导轨，830 mm