發動機裝配線PLC控制系統解決方案

2015-03-03 14:03
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  • 方案類別:行業產業

汽車發動機裝配線是一個對發動機順序裝配的流水線工藝過程,由若干自動站位、手動站位以及相關的輥道、轉臺等組成。按功能分主要有:輥道區域、清洗工位、擰緊工位、機器人工位、涂膠工位、發動機測量工位、發動機測漏工位、導管閥座壓裝工位以及手動控制工位等。

控制系統采用以PLC為核心,分散控制和集中管理的分布式控制模式;各獨立工位的控制系統之間通過網絡實現數據信息、資源共享,才能保證生產的連續性和穩定性。

一、系統結構

系統包括操作站、熱備服務器、PLC自動控制系統、網絡設備、現場I/O站以及外圍驅動設備等幾個部分。典型站位的PLC拓撲圖如下圖所示。

發動機裝配線PLC控制系統解決方案.jpg

操作員站:提供全漢化人機界面,實現控制系統的監控操作功能(操作、顯示、報表、報警、趨勢),并且可以接收工廠監控系統下發的生產指令,自動分配各工位生產所需資料,并通過網絡將生產計劃和各工位所需材料型號等下發給各相關PLC控制器。

服務器選用雙機熱備冗余服務器,帶磁盤陣列。

控制器選用SIEMENS CPU 315-2DP/PN和CPU414-3DP/PN,CPU自帶Profinet 以太網接口,通過交換機和上位機系統連接,上傳設備運行和故障狀態,接收生產指令。

現場I/O站使用現場總線技術,選用SIEMENS ET200eco系列模塊,帶Profibus通訊接口,安裝、接線方便,集成度高,可靠性好。

外圍設備包括MOBY無線讀寫設備、條碼和二維碼掃描槍、Comau機器人、伺服控制器、Atlas擰緊設備、測漏設備、串口打印設備、壓裝設備等,完成設備編號打印、序列號讀取、生產信息讀寫、工件擰緊、工件搬運、工件組裝等功能。

二、控制功能

根據裝配工位自動化復雜程度和工藝布局特點,裝配線電氣控制主要由區域控制(包括線體和手動工位)、自動和半自動工位以及返修工位組成。

— 區域控制

區域控制有手動和自動兩種工作模式,主要負責區域內線體驅動、移行、轉臺、手動和簡單半自動設備,并顯示上線產品信息和故障報警代碼。

— 手動工位控制

主要包括手動壓裝、涂膠、試漏、擰緊、擰松等。

— 半自動工位控制

主要包括半自動壓裝、涂膠、試漏、擰緊、擰松等。由人工輔助安裝發動機產品零部件,裝配工作由設備自動完成。

— 自動工位控制

主要包括對多軸擰緊機、翻轉機、試漏、壓機和測試設備等控制。配置獨立的PLC和HMI。

三、主要特點:

①    分散控制,集中管理,可靠性高;

②    網絡通信,信息共享,互通性好,實時性強;

③    站位分工明確,專業性強;配合高精度的測量器件和執行部件,實現高精度的定位和定量及高速度的工藝流程控制,節時高效。


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