Abstract: This article introduces the application of the BK-X86 series man-machine interface and the SIEMENS S7-200 series PLC in the double-disc take-up machine, and gives the key control system structure, program design structure and design.
1 Introduction
With the rapid development of the wire and cable industry, highly efficient, energy-saving and highly automated equipment is becoming more and more popular, and the double-disc take-up machine is one of them. The double-disc take-up machine is suitable for the wire take-up of the wire and cable industry. It has a high take-up speed, an automatic high-speed change of the fixed length, a speed reduction of the equipment during the change of the disk, non-stop, pneumatic lift of the upper and lower plates, pneumatic clamps. The functions such as the tight reel, it combines various detection elements of the pneumatic control box and has a complex control process. Due to the high reliability of PLC operation, the program is flexible and diverse, it is suitable for the environment, and is easy to use, easy to maintain and maintain. Therefore, the use of PLC and man-machine interface to control the dual disc take-up machine, instead of complex relay control circuit, is conducive to improving the reliability and utilization of equipment.
2, the structure and working principle of double disc take-up machine
This machine consists of a wire take-up device, a cable device, a tray device, a pneumatic system, and a body electrical control system. Pneumatic lifting up and down the line plate, pneumatic clamping and relaxation of the coil, the gas circuit is equipped with a pressure controller, when the pressure is lower than the set value, can not start or automatically stop. The line is automatically adjusted from empty to full. The cable is a separate motor drive and is controlled by either AC or DC speed control. Pitch (disc spacing) adjustment with AC variable frequency motor control. The motor used to change the disk is directly activated by an AC motor, which is controlled by a fixed-length signal to automatically change the disk from left to right (or from right to left), or manually changed by the operator and manually placed on and off the wire. The brake system uses a pneumatically controlled disc brake disc.
3, PLC program design
The double-disc take-up machine has a total of 15 control buttons, with 26 detection points as input points; there are 22 actuators in total, including 12 solenoid valves and 10 other actuators. The PLC of the control system adopts the digital I/O module and is responsible for the real-time collection of data such as fixed length, length, and speed, and the detection of the running status of the equipment. The outputs are used to adjust the coordination of various actions and used to control the left disk, Outputs of analog and digital switches such as the right-hand disk, cable, disk change, and alarms and warnings. The system uses STEP7-Micro/WIN32 V4.0 SP# programming software, according to the process flow and the requirements of the control system, programming with ladder diagram.
The programming method is mainly divided into four parts: manual adjustment, automatic adjustment, fault self-diagnosis, and logic output. Manual adjustment is used for device debugging, automatic adjustment is used for normal operation of the device, and fault self-diagnosis is used to display faults. Because many actions are reused, the same actions must be placed to prevent programming confusion. A and B of the flowchart are used during system operation until they are considered to be shut down or fail automatically. According to several on-site debugging experiences, summed up some types of faults: (1) gas circuit failure, leading to failure can not be reset, the system can not run; (2) electrical detection component failure, such as the detection element is not in place failure of the active components; ( 3) When the wire take-up machine changed the disk, the wire take-up speed was not equal, and the take-up line was too loose and too tight, resulting in the occurrence of a fault; (4) When the left disk was running, the right disk could not detect the signal to warn the user; when changing the disk The warning has not been eliminated, that is, a failure has occurred and the system is down; vice versa. When the fault occurs, the system displays the fault information on the human-machine interface through PLC detection and sends an alarm signal to remind the maintenance personnel to perform maintenance.
4, man-machine interface selection and design
The role of the human-machine interface is to monitor and manage the control system, such as displaying warnings or failures based on the detection results. Considering the fact that the system has more control signals and detection points, it is simple to pass information through the man-machine interface, as well as convenience considerations such as cost-effectiveness, and the BK-X86 series man-machine interface developed by Beijing Boji Industrial Controls has been selected. This series of man-machine interface is mainly divided into three parts: initial information transmission, warning and fault display alarm and status display data processing.
The PLC system detects all input signals, makes logical judgments according to the action requirements, and gives faults or warnings. The tri-color lamp is used to remind the site staff to perform on-site processing. At the same time, the touch screen displays the location of the fault and the corresponding solutions. The fault can be normalized after the fault is removed.
5. Concluding remarks
The stable and cost-effective man-machine interface of Beijing Boji Industrial Controls R&D and production is conducive to reducing the production cost of enterprises and ensuring product quality. Therefore, it has been widely used in enterprises. The use of PLC and man-machine interface to simplify the complex operation process is conducive to equipment maintenance and repair, and brings great social and economic benefits to the company. The system has won wide acclaim from customers for its excellent control performance in industrial field control.