外文翻譯---基于現(xiàn)場(chǎng)總線監(jiān)測(cè)系統(tǒng)的plc控制制造系統(tǒng)

1、<p>　　A Monitoring System For PLC Controlled Manufacturing System Based On Fieldbus</p><p>　　1. Introduction</p><p>　　The winding vacuum systems for plating metal such as zinc and aluminium

2、 on thin film are very common in the capacitance industry. The main goal is to increase as much as possible the film transport velocity while controlling the tension of the film. The tension and the speed of the film sho

3、uld be maintained at a reference value. The main concern is the coupling existing between film velocity and tension. There exist many sources of disturbances on the velocity (roller non-circularity, film slidi</p>

4、<p>　　winding chamber again. Obviously the pressure of winding chamber comes back to standard atmosphere pressure. And it will take about 20-30 minutes for winding chamber to reach the required pressure. Accordingl

5、y the output will decrease evidently. So a monitoring system to monitor tension fluctuation in order to avoid film break is very needful.</p><p>　　CC-Link is a field network system that processes both contro

6、l and information data at high speed, to provide efficient, integrated factory and process automation. Using CC-Link enables users to reduce the amount of control and power wiring required in the complicated production l

7、ine. Since users can select the suitable devices from more than 354 field devices</p><p>　　supported CC-Link it is easy to expand multi-vendor environment.</p><p>　　As for the communication of s

8、peed, this enables the communication with the sensor input which requires a high speed response and intelligent devices which requires a large amount of data communication.As one of CC-Links features, RAS functions such

9、as, stand-by master function, detaching slave station function and auto return function enable recovery from the communication fault and the system debug at start up time.As for test and monitoring function, confirmation

10、 of the data link status, hardw</p><p>　　In order to meet the quest for automation and flexibility, many complex manufacturing systems are controlled by Programmable Logical Controllers(PLC). This is because

11、 that PLC's are adaptable, modular, user-friendly and acquired at low cost. And that winding vacuum film plating system is just such a complex manufacturing system.</p><p>　　The paper presents an intelli

12、gent monitoring system based on CC-Link fieldbus which consists of upper personal computer and the lower Programmable Logic Controllers for the aim of control and information management. A new kind of technology using CC

13、-Link fieldbus is adopted in this monitoring system.</p><p>　　2. Structure of The Monitoring System</p><p>　　This fieldbus-based monitoring system has two arrangements including monitoring units

14、 in field and information management and control unit in control room. All intelligent monitoring units located nearby the winding vacuum machine have microprocessors, which have the following function as respective sign

15、al sampling, A/D conversion, data calculation, ect.Fieldbus is the most important connection between each discrete monitoring unit in slave stations and master station. Analog signal is supersede</p><p>　　Th

16、e quantities of intelligent monitoring units should be determined by practical needs. This system has five kinds of monitoring units: temperature, vacuum degree, roll diameter, film tension and transfer velocity.</p&g

17、t;<p>　　Whether the monitoring system could work normally depends on the performance of the sensors to a considerable degree. Their precision and stability has a direct influence on the monitoring system. Data obt

18、ained from these sensors are processed by PLC and displayed on HMI as Fig. 2 shown.</p><p>　　Intelligent monitoring module has two functions: on one hand it filters,amplifies and adjusts the output signal go

19、t from sensors to appropriate value which can be processed by PLC (FX series). On the other hand it carries through signal sampling, A/D conversion, data processing, software antiinterference,parameter calculation and tr

20、ansmits data to central control unit by virtue of communication interface of a PLC. </p><p>　　Central control unit (CCU) is the center of this monitoring system whichconsists of PC and RS232. It takes contro

21、l of working condition of each intelligent monitoring unit, gets data and abnormal information and saves them. In addition, CCU can be visited by upper user computers. Furthermore,it has been practicable to analyze data

22、and give a diagnosis for winding system by taking advantage of data management and fault diagnosis software.</p><p>　　The monitoring system makes use of CC-Link fieldbus which consists of communication modul

23、e and twisted-pair wire acting as communication medium. Sixty-four stations could be connected to this kind of fieldbus at most. The communication module is connected with monitoring units and respective stations through

24、 CC-Link fieldbus. Transmission distance even reaches 1.2km while communication rate of fieldbus is 156kpbs.</p><p>　　3. PLC PROGRAMMING</p><p>　　In this winding system, we use Mitsubishi A seri

25、es PLC as master station PLC because it has the characteristic of quick response and great ability of information processing. It is used to control the behaviors of the total winding system together with FX series PLCs o

26、f winding and unwinding system. The operating actions of the system and the sequence of these actions were edited beforehand into the control program by the designer. The control program sets a series of operations of th

27、e winding sy</p><p>　　The programming method used is the ladder diagram method. The PLC system provides a design environment in the form of software tools running on a host computer terminal which allows lad

28、der diagrams to be developed,verified, tested, and diagnosed. First, the high-level program is written in diagrams. Then, the ladder diagram is converted into binary instruction codes so that they can be stored in random

29、-access memory (RAM) or erasable programmable read-only memory (EPROM). Each successive instruc</p><p>　　representation of data associated with the inputs, outputs, and memory is based on the fact that the P

30、LC memory is organized into three regions: input image memory, output image memory, and internal memory[4].</p><p>　　The PLC program uses a cyclic scan in the main program loop such that periodic checks are

31、made to the input variables. The program loop starts by scanning the inputs to the system and storing their states in fixed memory locations (input image memory). The ladder program is then executed rungby-rung. Scanning

32、 the program and solving the logic of the various ladder rungs determine the output states. The updated output states are stored in</p><p>　　fixed memory locations (output image memory). The output values he

33、ld in memory are then used to set and reset the physical outputs of the PLC simultaneously at the end of the program scan[4].</p><p>　　As we know, logic control is a remarkable property of PLC, and it can be

34、 applied to efficiently handle analog data[2].</p><p>　　1) Analog data acquisition and transformation</p><p>　　Analog inputs and outputs such as pressure and temperature need to be measured on-l

35、ine. For instance, temperature is first acquired by the Platinum resistances. A signal transformation module then converts the measured resistance value into the voltage range of 1-5V. The output of this transformation m

36、odule is finally collected and transmitted back to the above PLC.</p><p>　　2) PLC control algorithms</p><p>　　The analog variables could be any controlled variable, e.g., temperature or pressure

37、 in our winding system. As a matter of fact, there exist two control modes, auto and manual. In the manual mode, operators modify the output values according to the desired levels; while in the auto mode, output values a

38、re regulated by the pre-designed control algorithms. It is worth</p><p>　　mentioning that the outputs of PLC are always incremental values. Although auto-tuning PID controllers can be employed here, manual t

39、uning is always used at the beginning of the production for routine initialization, and after that the system is switched to the auto mode. We emphasize that user's experiences oriented fuzzy logic controllers are ut

40、ilized here to further improve the production performance as well. A film tension control system using fuzzy logic controller (PLC) on PLC to cope with</p><p>　　To deal with the system with fixed model and p

41、arameter conventional PID is enough, but fixture is relative, in fact, the parameters of the winding system are variable in a definite range, therefore the controller must has robustness to obtain high performance. For t

42、his purpose, fuzzy reasoning is used to adjust the factors of PID, by this way the PID factors can be adjusted according to the changes of system state and plant parameters.</p><p>　　3) Servo motors control&

43、lt;/p><p>　　At the beginning the film is transferred at a low speed, and then the servo motors are accelerated to set speed to wind at high speed at about 8 miles per second. The film tension is detected by loa

44、d cells which control servo motors velocity to keep tension constant. The objective of control is not only to keep film tension constant but also to make winding velocity arrive at set value at least time. So the main pr

45、oblem is how to control servo motors accurately.</p><p>　　4, CONCLUSION</p><p>　　A monitoring system for PLC controlled manufacturing System Based on fieldbus for film plating production process

46、 is presented in this paper. It has been successfully on operation in practical production since 2003. Promising results have demonstrated its great advantage in practice as well as significant profit improvement. &

47、lt;/p><p>　　基于現(xiàn)場(chǎng)總線監(jiān)測(cè)系統(tǒng)的PLC控制制造系統(tǒng)</p><p><b>　　1 導(dǎo)言</b></p><p>　　用電鍍金屬做成的蜿蜒的真空系統(tǒng)，就像是鋅和鋁薄膜那樣是非常普遍的電容行業(yè)。他的主要目標(biāo)是當(dāng)控制張力的膜時(shí)能盡可能增加膜的運(yùn)輸?shù)乃俣?。膜的緊張程度和速度應(yīng)該以一個(gè)參考價(jià)值而被保存起來。而主要的問題存在于膜的速度和張力之間

48、的耦合。它們之間的速度問題存在很多干擾資源（輥非圓，膜滑動(dòng)）。如果傳遞的速度變動(dòng)的話，那么對(duì)膜的治療將會(huì)變的不均勻。另一個(gè)方面，不恰當(dāng)?shù)木o張局勢(shì)將會(huì)導(dǎo)致褶皺或者是膜破裂。一旦發(fā)生膜破裂，經(jīng)營者需要再次開放清盤商會(huì)。很明顯，清盤商會(huì)的壓力將會(huì)反作用于標(biāo)準(zhǔn)大氣壓的壓力。而要達(dá)到清盤商會(huì)所需的壓力需要20到30分鐘的時(shí)間。因此，產(chǎn)量將明顯減少。所以，用一個(gè)監(jiān)測(cè)系統(tǒng)，監(jiān)測(cè)緊張的波動(dòng)程度，以避免膜破裂是非常必要的。</p><

49、p>　　CC-Link是一個(gè)外地網(wǎng)絡(luò)系統(tǒng)，它以高速傳送控制力度和數(shù)據(jù)信息，以提供效力，結(jié)合代理，過程自動(dòng)化。使用CC-Link可以使使用者減少數(shù)量控制和需要在復(fù)雜的生產(chǎn)線下的電源線路。當(dāng)用戶可以從支持CC-Link的多余的354個(gè)領(lǐng)域的設(shè)備中選擇出合適的設(shè)備，那么多供應(yīng)商環(huán)境的擴(kuò)展將會(huì)變的很容易。</p><p>　　至于交流的速度，使得通信和傳感器輸入需要高速反應(yīng)和智能設(shè)備，需要大量的數(shù)據(jù)通信。作為一個(gè)C

50、C-Link的功能，F(xiàn)AS的功能是：tand-by的主功能，分離站的功能，自動(dòng)分離功能，這些功能使得在通信故障和系統(tǒng)調(diào)試時(shí)自動(dòng)恢復(fù)過來。至于測(cè)試和監(jiān)測(cè)職能，對(duì)確認(rèn)數(shù)據(jù)連接狀態(tài)，硬件測(cè)試和電路測(cè)試都是可行的。CC-Link的網(wǎng)絡(luò)圖顯示如圖1所示。</p><p>　　CC-Link的監(jiān)測(cè)系統(tǒng)是由主站，奴隸站，個(gè)人電腦，逆變器，伺服電機(jī)，遠(yuǎn)程I/O單元等組成。</p><p>　　為了滿足追求

51、自動(dòng)化和靈活性的要求，許多復(fù)雜的制造系統(tǒng)都是由可編程控制器（PLC）來控制的。這是由PLC的適應(yīng)性強(qiáng)，模塊化，便于使用和成本低等優(yōu)點(diǎn)決定的。真空卷繞鍍膜就是這樣一個(gè)復(fù)雜的制造系統(tǒng)。</p><p>　　本文介紹了基于CC-Link現(xiàn)場(chǎng)總線的智能監(jiān)控系統(tǒng)，其中包括個(gè)人電腦和目的是控制和信息管理的可編程邏輯控制器。使用CC-Link現(xiàn)場(chǎng)總線提出了一種新技術(shù)是為了通過這一監(jiān)控系統(tǒng)。</p><p&g

52、t;<b>　　2結(jié)構(gòu)監(jiān)測(cè)系統(tǒng)</b></p><p>　　基于現(xiàn)場(chǎng)總線的監(jiān)測(cè)系統(tǒng)有兩個(gè)安排，包括在領(lǐng)域里的監(jiān)測(cè)單位，信息管理和在控制之中的控制單元。位于清盤真空機(jī)附近的所有智能監(jiān)測(cè)單位都有微處理器，其中有以下功能，各自的信號(hào)采集，A/D轉(zhuǎn)換，數(shù)據(jù)計(jì)算等等。奴隸站和主站之間的每個(gè)離散監(jiān)測(cè)單位是現(xiàn)場(chǎng)總線最重要的部分。為了進(jìn)行雙向通信，模擬信號(hào)被數(shù)字信號(hào)所取代。這有利于運(yùn)營商在控制室里進(jìn)行控制，

53、核查和參數(shù)設(shè)置。這樣的結(jié)構(gòu)，一方面，提高了監(jiān)測(cè)系統(tǒng)的精度和抗干擾能力，另一方面，它也節(jié)省了投資成本。</p><p>　　圖1 CC-Link的網(wǎng)絡(luò)圖</p><p>　　數(shù)字職能監(jiān)測(cè)單位應(yīng)取決于實(shí)際需求。該系統(tǒng)有五種監(jiān)測(cè)單位：溫度，真空度，軋輥直徑，膜的張力和轉(zhuǎn)移速度。</p><p>　　監(jiān)測(cè)系統(tǒng)是否能夠正常工作在很大程度上依賴于高性能的傳感器。其精度和穩(wěn)定性，

54、直接影響了監(jiān)測(cè)制度。從這些傳感器上獲得的數(shù)據(jù)經(jīng)過PLC的處理，顯示在人機(jī)界面上，如圖2所示。</p><p>　　智能監(jiān)測(cè)模塊有兩個(gè)功能：一方面，它的過濾器，放大和調(diào)節(jié)輸出信號(hào)的傳感器通過PLC的處理可以得到適當(dāng)?shù)闹担‵X系列）。另一方面，它憑借通信接口的可編程控制器進(jìn)行數(shù)據(jù)采集，A/D轉(zhuǎn)換，數(shù)據(jù)處理，軟件抗干擾，參數(shù)計(jì)算等將數(shù)據(jù)傳輸?shù)街醒肟刂茊卧?lt;/p><p>　　中央控制單元（CC

55、U）是這個(gè)監(jiān)測(cè)系統(tǒng)的中心，其中包括PC機(jī)和RS232。它的工作狀態(tài)是控制智能監(jiān)測(cè)的每個(gè)單位，將得到數(shù)據(jù)和異常信息進(jìn)行處理以挽救它們。此外，控制器可以被用戶計(jì)算機(jī)所訪問。并且，它已經(jīng)切實(shí)可行的分析出了數(shù)據(jù)，并且利用數(shù)據(jù)管理和故障診斷軟件對(duì)數(shù)據(jù)進(jìn)行了診斷。</p><p>　　該監(jiān)測(cè)系統(tǒng)利用CC-Link現(xiàn)場(chǎng)總線構(gòu)成的模塊和雙絞線作為通信介質(zhì)。最多可以有64個(gè)站可以連接到這樣的現(xiàn)場(chǎng)總線中。該通信模塊是通過CC-Lin

56、k現(xiàn)場(chǎng)總線與檢測(cè)單位和各個(gè)站連接起來的。當(dāng)現(xiàn)場(chǎng)總線的通信速率為156kps時(shí)傳輸距離可以達(dá)到1.2公里。</p><p>　　圖2 在HMI上的監(jiān)控顯示</p><p><b>　　3 PLC的編程</b></p><p>　　在這個(gè)系統(tǒng)中，我們使用三菱系列的PLC作為PLC的主站，這是由于它的快速反應(yīng)和巨大的信息處理能力的特點(diǎn)所決定的。它是用

57、來控制總卷繞系統(tǒng)與FX系列的PLC纏繞系統(tǒng)和舒展共存系統(tǒng)的行為的。系統(tǒng)的經(jīng)營行為和這些行為的排列都是由設(shè)計(jì)者事先編輯好的?？刂瞥绦蛞?guī)定了一系列卷繞系統(tǒng)的行動(dòng)，講述了PLC是如何控制系統(tǒng)的。目前國家的所有傳感器或執(zhí)行器都被作為一系列的輸入，輸出和旗幟信號(hào)而保存在PLC的內(nèi)存中。因此，PLC程序是在PLC控制的制造系統(tǒng)中的監(jiān)測(cè)基礎(chǔ)。</p><p>　　PLC的編程采用梯形圖的方法。它提供了一個(gè)設(shè)計(jì)環(huán)境，這個(gè)環(huán)境就是

58、軟件工具運(yùn)行在主機(jī)終端，以便于梯形圖的開發(fā)，驗(yàn)證，測(cè)試和診斷。首先，高層次的計(jì)劃使用圖表，然后，梯形圖轉(zhuǎn)換成二進(jìn)制指令代碼，以便于它們可以存儲(chǔ)在隨機(jī)存取存儲(chǔ)器（RAM）或可擦除可編程只讀存儲(chǔ)器（EPROM）。每個(gè)指令由CPU解碼和執(zhí)行。CPU的程序是用來控制操作的內(nèi)存和I/O裝置，并根據(jù)程序處理數(shù)據(jù)。PLC上的每個(gè)輸出和輸入的連接點(diǎn)上有一個(gè)地址用于I/O位的識(shí)別。數(shù)據(jù)的直接代表的方法與輸入，輸出和記憶有關(guān)，基于這樣一個(gè)事實(shí)，將PLC的內(nèi)

59、存分為三個(gè)區(qū)域：輸入圖像存儲(chǔ)，輸出圖像存儲(chǔ)，內(nèi)存。</p><p>　　PLC程序采用主程序循環(huán)掃描的方法，例如輸入的變數(shù)定期檢查。該循環(huán)項(xiàng)目的啟動(dòng)是采用掃描輸入系統(tǒng)和存儲(chǔ)器在內(nèi)存中的固定位置的方法進(jìn)行的（輸入圖像記憶）。其它的程序是按照一個(gè)接一個(gè)的方式執(zhí)行的。掃描程序和各種梯形量的解決決定了輸出量。更新的輸出量存儲(chǔ)在固定的內(nèi)存中（輸出圖像記憶）。在程序結(jié)束時(shí)，內(nèi)存中的量被用來設(shè)置和從新設(shè)置PLC的物理輸出。&l

60、t;/p><p>　　正如我們所知，邏輯控制器是PLC的一個(gè)重要組成部分，它可用于有效處理模擬數(shù)據(jù)。</p><p>　　1）模擬數(shù)據(jù)采集和轉(zhuǎn)換</p><p>　　模擬的輸入和輸出就像是壓力和溫度需要在線測(cè)量一樣。舉例來說，溫度是測(cè)量鉑的電阻以獲得的所需要的量。經(jīng)過信號(hào)轉(zhuǎn)換模塊轉(zhuǎn)換后，測(cè)量電阻的電壓值在1-5V之間。輸出模塊的這種轉(zhuǎn)變是最后收集然后再返回給PLC的。&

61、lt;/p><p>　　2)PLC的控制算法</p><p>　　模擬量可以是任何形式的變量，如我們的卷繞系統(tǒng)中的溫度和壓力。事實(shí)上，存在著兩種控制方式，自動(dòng)和手動(dòng)。在手動(dòng)模式下，運(yùn)營商可以根據(jù)期望的水平修改輸出值，而在自動(dòng)模式下，輸出量受預(yù)先設(shè)計(jì)的控制算法所規(guī)定。值得一提的是，PLC的產(chǎn)出總是增加的。雖然PID的控制器可以被控制在這里，但手動(dòng)諧調(diào)的生產(chǎn)初始化一開始時(shí)就被使用，而且，在那個(gè)系統(tǒng)

62、之后就切換到自動(dòng)模式。我們強(qiáng)調(diào)，用戶的面向模糊邏輯控制器的使用的經(jīng)驗(yàn)，也能進(jìn)一步改善這里的生產(chǎn)性能。膜的張力控制系統(tǒng)采用PLC的模糊邏輯控制器（PLC）,以應(yīng)付卷繞系統(tǒng)的不確定性。模糊邏輯計(jì)算法，實(shí)現(xiàn)了基于PLC的指示。</p><p>　　對(duì)于固定的模式和常規(guī)PID的參數(shù)處理已經(jīng)達(dá)到了一個(gè)很好的階段了，但是事物總是相對(duì)的，事實(shí)上，卷繞系統(tǒng)的參數(shù)設(shè)定在一定范圍內(nèi)，因此，控制器必須具有魯棒性，以獲得較高的性能。為此

63、目的，模糊推理被用來調(diào)整PID的因素，用這樣的方法，PID的因素可以根據(jù)系統(tǒng)狀態(tài)和植物參數(shù)的變化來衡量。</p><p><b>　　3)伺服電機(jī)控制</b></p><p>　　膜一開始時(shí)是以很低的速度轉(zhuǎn)動(dòng)的，然后伺服電機(jī)開始加速，最后大概達(dá)到每秒鐘8英里。膜的張力是由負(fù)載細(xì)胞控制的，它控制伺服電機(jī)以保持張力恒定?？刂频哪繕?biāo)不僅是保持膜的張力不變，而且也使繞組在最少

64、的時(shí)間內(nèi)達(dá)到設(shè)定的值。所以主要的任務(wù)是如何控制伺服電機(jī)能準(zhǔn)確的工作。</p><p><b>　　4 結(jié)論</b></p><p>　　PLC的監(jiān)測(cè)系統(tǒng)是用于控制制造系統(tǒng)的?；诂F(xiàn)場(chǎng)總線的鍍膜生產(chǎn)過程在本文當(dāng)中已經(jīng)給了很充分的說明了。自從2003年以來它已經(jīng)在實(shí)際生產(chǎn)中得到了運(yùn)用。它的成果已經(jīng)證明了它具有很大的優(yōu)勢(shì)，而且它在實(shí)踐中的利潤(rùn)也將會(huì)有很大的改善。</p