LNS-Y-6
LNS-Y-6
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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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