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在企業搬遷工作中，原來在包裝崗位有兩臺其他品牌的小型 PLC在使用，分別控制堆垛崗位和封切熱縮崗位。目前該型號產品已經被淘汰，而在搬遷后發現，PLC上電無反應，必須要進行更新換代。
　　1　工藝原理
　　本包裝設備，完成對本廠建材產品的包裝，包裝材料使用PE 熱縮塑封膜。主要工藝步驟包括：①堆垛;②封切：對塑料膜進行切斷和封口;③熱縮：使PE膜加熱收縮包裹產品。
　　2　方案選型
　　2.1 控制方案設計
　　針對本系統的特點，適合采用集成了IO點的小型PLC。而溫度可以單獨交給溫控表進行控制，速度由變頻器進行調節，為了提高系統操作性能，溫控表和變頻器與PLC進行MODBUS通信，交換數據。同時，PLC通過網線連接至中控室上位機，完成數據采集、顯示和必要的操作。
　　2.2 PLC選型及IO表設計
　　根據現場設備匯總需要輸入點13個，輸出點12個，使用 S7-200 SMART系列的SR40型號CPU并設計IO表。
　　2.3 其它主要電氣設備選型
　　另外選擇了1臺安川V1000變頻器和2臺山武SDC36溫控表分別進行速度和溫度的控制，它們都支持通過MODBUS通信協議與 S7-200 SMART進行通信。
　　2.4 確定通訊方案
　　(1)上位機以太網通信方案本工廠使用的上位機為亞控公司生產的組態王上位機組態軟件，經過查找發現組態王已經更新了S7-200 SMART的驅動，驅動名稱：S7 TCP.DLL，驅動版本：60.1.24.30。
　　(2)MODBUS通訊方案安川V1000變頻器和山武SDC36溫控表具有非常相似的指令結構，能夠方便地接入系統。
　其中讀取和寫入的功能碼分別是03H和10H。
　　3　編程與調試
　　3.1 IO控制程序編程與調試
　　塑封膜包裝線中堆垛和封切工序的動作最為復雜，而且各動作也存在著邏輯關系，為了準確執行各封切動作，采用步進控制。其他的只采用普通的邏輯控制即可。
　　3.2 MODBUS通信程序編程與調試

Schneider Modicon AS-BZAE-204 High Speed Counter ASBZAE204

Schneider Modicon AS-B805-016 800 I/O MODULE

Schneider Modicon AS-B805-016

Schneider Modicon Motion Module M AS-B885-110 ~REPAIRED SUR~

Schneider Modicon OUTPUT MODULE AS-B828-016

Modicon 992 019 1002 Robot Teach Pendant HHTP

Siemens Analog Input Sub-Module 6ES5 498-1AA51

SEALEDASA5540-AIP20-K9 CISCO 5540 W/AIP-SSM-20 SW HA 4GE1FE 3DES/AES

Siemens MS300 Circuit Board MS3OO 6FX1113-4AD01 6FX11134AD01 6FX1113-4ADO1

SIEMENS SINUMERIK 6FC5203-0AF02-0AA1 no box Free Ship

Spirent SX-7410B Communication Analyzer Module

SIEMENS 6SN1123-1AA00-0CA0 SIMODRIVE 50A WRTYFAST SHIP

SIEMENS 6SN1146-1BB01-0BA2 SIMODRIVE 611 INFEED/REGEN. FEEDBACK MODULE

SIEMENS 6FC5247-0AA02-1AA0 6FC5 247-0AA02-1AA0 SINUMERIK 840D PCI/ISA Adapter

AirTAC Solenoid Valve 4V120-M5 in Box

ALLEN-BRADLEY 160-BA01NPS1P1 0.5HP 460VAC Control. in good condition

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 88288

ADEPT TECH 10845-72000 USPP 1084572000

(2018) 1 SYMAX INPUT MODULE ANALOG RIM125 SQUARE D (2018)

INDRAMAT DSC3.1-150-115 USPP DSC31150115

TEXAS INSTRUMENTS PLC 555-1101 NSPP 5551101

FANUC A02B-0072-C023 USPP A02B0072C023

CUTLER HAMMER FDPW367T USPP FDPW367T

RELIANCE ELECTRIC 0-57552-4A USPP 0575524A

MODICON PC-E984-685 USPP PCE984685

JOSLYN CLARK 5003-2001-11 NSPP 5003200111

Siemens 6ES5 373-1AA81 -FS- 6ES53731AA81

Siemens 6ES5-605-0UB12 USPP 6ES56050UB12

SIEMENS 6ES5-375-0LC21 USPP 6ES53750LC21

Siemens 6ES5 375-1LA15 -- 6ES53751LA15

Siemens Bus I/O Module 6ES5 700-8MA21

SIEMENS 6SE3212-0DA40 6SE32120DA40 IN BOX

Siemens TP27-6 6AV3 627-1NK00-0AX0 Touchscreen Glass

Siemens 6EW1380-4AB01

MARCONI ATM SINGLE MODE INTERFACE MODULE FOR THE ASX200BX NM4155SMIRD

XYCOM XVME-660 VME BUS XVME 660 XVME660 Intel

Siemens 6ES7 253-1AA22-0XA0 6ES72531AA220XA0 in Box

SIEMENS OPM2 6SE3 290-0XX87-8BF0 OPERATOR INTERFACE

Reliance 0-51839-8

Schneider Modicon AS-B360-001 Relay Output Module ASB360001

Schneider Modicon AS-984B-832 USPP AS984B832

Schneider Modicon AS-P453-612 USPP ASP453612

Schneider Modicon AS-B801-000 ASB801000 B801 Spare Slot

Schneider Modicon AS-B062-P00 / 100-037

MODICON PLC MODULE AS-B824-016 24 VDC OUTPUT

SIEMENS SIMATIC S5 ANALOG INPUT MODULE CAT6ES5464-8MC11

Siemens 6ES7 331-7KF02-0AB0 -- 6ES73317KF020AB0

SIEMENS SIMATIC HMI OP3 6AV3503-1DB10 Operator Panel

SIEMENS 6DD1601-0AE012 mo. warrantyFree UK/EU ShippingPrice Inc UK VAT

SIEMENS Sinumerik Panelfront 6FC5203-0AF02-02-0AA0 Version L_6FC52030AF02020AA0

SIEMENS 90 DAYS WARRANTYDigital High Performance Control Board

SIEMENS Simodrive 6SN1118-0DJ21-0AA0 6SN11180DJ210AA0

SIEMENS Control Rack 6FC3761-2FA Z_ Genumerik 3G Unit Sinumerik 6FC 3761

AFP8551 Cable USB version for Panasonic FP1/FP3/FP5

Allen-Bradley 2706-E43J32B1 E43J32B1 ser A rev B GOOD

ABB ACH501-050-4-00P2 ACH500 VARIABLE TORQUE AC 50HP 480V-AC MOTOR DRIVE B228004

Acterna TB / MTS-8000 11.1G Optical Ethernet Transport Module T-BERD / MTS 8000

6ES7314-5AE10-0AB0 Brand , Factory Sealed,

87 BARKSDALE 423X-13 PRESSURE TRANSDUCER S 0-3000 PSIG 0-30 VDC NR

SIEMENS 6SE9-221-3DC40 USPP 6SE92213DC40

BANNER ENGINEERING DMSK4848F1 NSFP DMSK4848F1

AUTOMATED LOGIC M0320 NSFP M0320

MODICON AS-9003-821 USPP AS9003821

INDUSTRIAL DEVICES EC5-X-2010B-150-MS6E/MF1-MTE1-42X USPP EC5X2010B150MS6E

BOSTON GEAR F732-60-B7-G USPP F73260B7G

YASKAWA ELECTRIC R84H-M USPP R84HM

Siemens 6ES5-454-7LA11 NSFP 6ES54547LA11

SIEMENS 6ES5 752-0AA12 6ES57520AA12

SIEMENS S5 6ES5 454-7LA11 OUTPUT MODULE

Siemens S5 PLC Cable 6ES5712-8AF00 6ES5 712-8AF00

Siemens 6ES7195-7HD10-0XA0 NIB

Siemens Servo Motor 1FT6 ERN 1387 2048 62S14-70K 0,00

Siemens 3VU9135-1AB04

Hp 583501-001 Hp Bluetooth Module Interface

WELLS FARGO SIEMENS SXR-2 ADDRESSABLE POINT INTERFACE MODULE EXACTPOINT SMT APT

Siemens 6ES5 246-4UA41 ping Worldwide

Siemens LOGO! DM8 12/24R 6ED1055-1MB00-0BA1 NIB

Omron C200H-CN131

Schneider Modicon AS-HDTA-200/ASHDTA200 Primary rack OFFERS

Schneider Modicon 8-point I/O Module ASbdep210 AS-bdep-210

Schneider Modicon AS-I425-100 USPP ASI425100

Schneider Modicon MODICON/ AS-M485-004 MEMORY BOARD XLNT

Schneider Modicon AS-J878-000

Schneider Modicon TSX Compact AS-BDEP-216 Discrete Input

TELEMECANIQUE XBTGT2110 Touchscreen Glass

Schneider Telemecanique TWDPTO220DT TWDPT0220DT FreShip

Siemens TI 505-6408 8 Ch Word Output Module

Siemens 6AV3505-1FB12 6AV35051FB12 COROS OP5

SIEMENS Sinumerik 6FX1120-3BB01 PC Board

Ethernet Communication Module USB SPI ENC28J60 Remote

SIEMENS SIMODRIVE POSMO CD/CA IP 6SN2703-3AA10-0BA1

SIEMENS SIMODRIVE 6SN1145-1BA02-0CA1SINUMETIK 840D NCU-BOX 6FC5247-0AA002ZA

SIEMENS 6 Genuine Printronix 107675-005 OCR Ribbon

Allen-Bradley AB 1746-OG16 /C 1746OG16 TTL Output Module NIB

ABB 086363-002 PC BOARD 086363002

AC TECHNOLOGY M34400B NSFP M34400B

A06B-6058-H025 Drive Fanuc

8 Stec LF-310A-EVD Liquid Mass Flow Controller TEB 0.5g/min

SECO SV3440-01000 USPP SV344001000

ALLEN BRADLEY 6500-PS7DSP USPP 6500PS7DSP

ALLEN BRADLEY 2727-T7P30D1F NSFP 2727T7P30D1F

INDUSTRIAL DEVICES B8962NP USPP B8962NP

GENERAL ELECTRIC DS215SLCCG2AZZ01B USPP DS215SLCCG2AZZ0B

YAMATAKE 82114927-001 USPP 82114927001

MARPOSS 7534250000 USPP 7534250000

Siemens 6ES5-301-5CA12 USPP 6ES53015CA12

SIEMENS 6ES5 421-8MA12 6ES54218MA12

SIEMENS S5 6ES5 312-5CA12 IM312 including cable

Siemens CPU Module 6ES5 944-7UB21 7300

Siemens 6ES7 215-2AD00-0XB0 6ES72152AD000XB0 DP

Siemens OP27 6AV3627-1JK00-0AX0 Operator Display Panel

RELEASE SuperMicro X9DRD-IF Motherboard FULL MFR

Texas Instruments 5TI-1031-1

Telemecanique LA1 LC580BD Interface Module

TSXSCY21601 Modicon Premium 485 MP TSX-SCY-216-01

Siemens DCS Module 6DS1701-8AB IN Box, seal opened,

Modicon MM-PM15-401

Schneider Modicon REMOTE I/O PROCESSOR S908 RIO INTERFACE MODULE AS-J890-101

Schneider Modicon ASBADU204 Compact Analog Input AS-BADU-204

Schneider Modicon AS-BFRQ-254C USPP ASBFRQ254C

Schneider Modicon AS-BZAE-204

Schneider Modicon AS-P120-000 P120 Compact 115/230V AC Power Supply WARRANTY

Schneider Modicon High Speed Counter AS-B883-001

Schneider Telemecanique Overload Relay LRD16KN

SCHNEIDER AUTOMATION MODICON TSX 140DA154000 INPUT MODULE

PWR-950-AC 950W AC P/S FOR CISCO 7600 AND CAT 6500

SIEMENS 6ES5451-4UA12 OUTPUT MODULE 32POINT .5AMP 24VDC IN A BOX

SIEMENS 6DD1640-0AC012 mo. warrantyFree UK/EU ShippingPrice Inc UK VAT

LS INDUSTRIAL G7L-CUEB RS-232C COMMUNICATION MODULE

SIEMENS Simodrive 6SN1123-1AB00-0HA1

SIEMENS Sinumerik 840C/840CE P/Supp 6FC5114-0AA01-1AA0

SIEMENS /MOORE 15994-21-4 PC BOARD MODULE XLNT

Allen-Bradley SLC 500 Cat. 1746-OA16 Output Module Series D

ALLEN BRADLEY RIGHT HAND DOOR HARDWARE KIT 1494V-L3

ABB SACE E2B/E-1600 OUT OF

A06B-0148-B088#0075 FANUC SERVO MOTORS REMANUFACTURED

6x500m/spool Fujikura Panda Type Polarization Maintaining Fiber 1300nm

ORMEC GN3-J594001 USPP GN3J594001

ALLEN BRADLEY 1771-DMC4 NSPP 1771DMC4

ALLEN BRADLEY 1336S-B007-AX-EN-GM1-L4 USPP 1336SB007AXENGM1

GENERAL ELECTRIC DS200IMCPG1CCB USPP DS200IMCPG1CCB

TB WOODS WFC4020-0CHT USPP WFC40200CHT

SQUARE D ATV-58HD23M2XZ USPP ATV58HD23M2XZ

CONTROL TECHNOLOGY INC 2553-1 NSPP 25531

Siemens 6ES5 951-7LD21 6ES59517LD21

Siemens 6ES5 460-7LA11 -

SIEMENS 6ES5-752-0AA12 USPP 6ES57520AA12

Siemens 6ES5 498-1AA11 USPP 6ES5498111AA11

Siemens 6AV6641-0AA11-0AX0 OP73 6AV66410AA110AX0

Siemens LOGO 24RL 6ED1053-1HA00-0BA0

RSP720-3C-10GE Cisco Switch Processor 720 W/10 Gigabit EN uplinks Router

Telemecanique TSX SUP 702

SIEMENS Simatic 6ES5441-4UA11 Comm. Interface Module

Wago 750-493/000-001 3-phase power measurement module

Siemens 6SE7090-0XX85-1DA0 ping Worldwide

Modicon AS-P464-001

Schneider Modicon EXPRESS 75 BALLPOINT REFILLS- BLACK FINE-SAME AS 575-FIT K2 PEN

Schneider Modicon AS-B551-001 ASB551001 G266

Schneider Modicon AS-B873-011 USPP ASB873011

Schneider Modicon AS-B825-016 24VDC Input Module True High

Schneider Modicon Fast Input Module AS-B829-116 ASB829116 - Lot of 4

Schneider Modicon AS-J878-000 Modem Module ASJ878000

SCHNEIDER ELECTRIC 140DAO84000 TSX QUANTUM OUTPUT MODULE AC OUT 24-230V

SIEMENS 505-6308 WORD INPUT MODULE 5056308

Reliance Shark 57C554 Remote I/O Interface 57C-554

Siemens 9330 9330DC-126-0ZZZZA Power Meter Display ION Profibus Access

SIEMENS Sinumerik Module Modul #6FC5111-0CA03-0AA2

Prosoft MVI56-GSC Communications Module 2

SIEMENS Module # 6SN1146-1BB00-0EA1 Simodrive 611

SIEMENS SIMODRIVE 6SN1145-1BA01-0DA1SINUMETIK 840D NCU 6FC52476SN11236FC5357

SIEMENS 6FC3984-1FB Tape Reader - Used

Allen-Bradley2707-MVH232MicroViewTerminal

Allen Bradley Terminal Board 9101-1780 Amphenol /Sealed

ABB IRB6600 ROBOT IRB 6600

ZEBRA 090-401-00203-09 USPP 0904010020309

(RR11-1) 1 NIB WESTINGHOUSE A202K3CAZ 100A 600VAC CONTACTOR RR11-1

MITSUBISHI FR-A240-E-37K-TF USPP FRA240E37KTF

ALLEN BRADLEY 1336T-MCB-SP51B NSPP 1336TMCBSP51B

GENERAL ELECTRIC 44B377098-G01 NSPP 44B377098G01

FISHER ROSEMOUNT 3051-CG4A02A1AH2M5 USPP 3051CG4A02A1AH21

SIEMENS 6ES5-902-3SA12 USPP 6ES59023SA12

REXROTH 0-608-820-092 NSPP 0608820092

TEXAS INSTRUMENTS PLC 555-1102 USPP 5551102

Siemens 6ES5 521-8MA21 CP521 SI COMMUNICATION MODULE RE

Siemens 6ES5-981-0HA21 USPP 6ES59810HA21

SIEMENS 6ES5-451-7LA11 OUTPUT MODULE 6ES54517LA11

Siemens 6ES5 316-8MA12 USPP 6ES53168MA12

Siemens S5 Digital Output / 6ES5 441-8MA11

Siemens C98043-A7007-L1-3

Siemens 6ES5 441-4UA11 6ES54414UA11

Square D 8030 CRM-601

Schneider Electric TSXFPCG010 Interface Module FIP/PCMCIA

WMD PDO PHASE DISPLACEMENT OSCILLATOR MODULAR EURORACK MODULE

SIEMENS 6ES7621-6BD02-0AE3 SIMATIC C7-621 ASI ping Worldwide

SIEMENS Touch Glass + Protective film TP177A 6AV6642-0AA11-0AX1

Seco SE2302

Schneider Modicon ASH827103 PERFECT 800 Series Rack AS-H827-103

Schneider Modicon AS-B571-001 NSFP ASB571001

Schneider Modicon CNC Memory Board AS-506P-F12

Schneider Modicon AS-H810-208 USPP ASH810208

Schneider Modicon AS-B840-108 Reed Relay Output

MODICON 5-1/2" PANELMATE PLUS INTERFACE MM-PMC1-100

Siemens 8 Point Input Module Model:505-7028 NIB

Schneider Modicon Premium TSXDEY16A4 TSX DEY 16A4 120VAC Input NIB

Siemens MODULE 8 PT IN 24VDC 5PIN EM141 6ES7-141BF30-0X

SIEMENS Sinumerik 6FX1112-0AA01 E Stand D & 01

SIEMENS SIMATIC S7 CP341 RS232 COMMUNICATIONS MODULE 6ES7 341 6ES7341-1AH01-0AE0

SIEMENS 6SN1123-1AA00-0DA2 ( 6SN11231AA000DA2 ) NIB

SIEMENS 6SN1123-1AB00-0HA1 6SN1 123-1AB00-0HA1 SIMODRIVE 611 Power Module 8A

SIEMENS 6FC5210-0DF05-0AA0 SINUMERIK PCU 50 6FC52100DF050AA0 NIB

AllenBradleyVersaView6176M-15PN/B6176M15PN

ALLEN-BRADLEY 1201-DMA HMI DOOR MOUNT BEZEL

ABB CIRCUIT BOARD DSQC 302

ADEPT TECH 30340-40000 USPP 3034040000

(4) Samsomatic Switches PWA 27-1039 _ PWA271039 _ 143PC03D

INDRAMAT MAC071C-0-JS-4-C/095-A-0/W1520LV USPP MAC071C0JS4C095A

TOPEX 2200-HYC USPP 2200HYC

FANUC A06B-0651-B211 USPP A06B0651B211

DANAHER MOTION MX2000-1C NSFP MX20001C

RELIANCE ELECTRIC 30V4151 USPP 30V4151

MOTOROLA MVME2700-761-I/O USPP MVME2700761IO

LENZE EVS9323-ET NSFP EVS9323ET

Siemens 6ES5 377-0AA32 -- 6ES53770AA32

Siemens 6ES5-701-3LA11 USPP 6ES57013LA11