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本文介紹了西門子 S7-200 SMART PLC、SMART LINE 觸摸屏以及 SINAMICS V20 變頻器在套標機上的應用，闡述了設備工藝流程、控制系統的配置選型、軟件設計和實現的功能。經測試，該方案能完全滿足高速套標機的各項技術要求，運行穩定，性能良好。
　　關鍵詞：S7-200 SMART SMART LINE SINAMICS V20 套標機
1 引言
　　套標機是一種將熱縮塑膠商標桶卷自動切斷，準確套入容器的包裝機械，配合后熱收縮工序，將標簽完好地固定于容器適當位置。
　　上世紀 90 年代以來，我國的快速消費品包裝工業得到了迅速發展，快速消費品企業的生產集中度和自動化程度在不斷提高，包裝設備在向大型化、快速化、高效化、自動化方向發展。套標機作為后段包裝技術含量較高的設備之一，其優良的高速穩定性能，獨特的靈巧化設計，人機協和的安全模式，得到了廣大客戶的充分肯定。套標機的使用大大降低了套標環節的人力物力，現已廣泛應用于啤酒飲料、化工、醫藥等行業。
2 套標機工藝原理
　　2.1 套標機結構
　　從工藝功能的角度進行劃分，套標機的結構可分成以下 9 單元。并如圖 1 所示。
　　(1) 供料組：由變頻器帶動供料電機旋轉，用以傳送標簽膜料;
　　(2) 電眼架組：使用光纖電眼傳送信號，提供下標伺服做定尺寸輸送，電眼位置可高低調整;
　　(3) 驅動組：采用雙驅送料機構，由下標伺服電機驅動。用于固定中心柱和下標動力傳動;
　　(4) 刀盤組：采用同步輪機構，由伺服電機驅動，當進瓶光電 7 給出信號時，切刀電機帶動刀片旋轉一周將標簽切斷;
　　(5) 刷下組：采用同步調整機構，將刷下兩組傳送輪調整至中心柱下方與滾輪輕微接觸，待標簽通過時以較高轉速將標簽套入瓶子;
　　(6) 分瓶螺桿：將欲套標瓶做等距分開，進入帶瓶組，速度由變頻器控制，與輸送帶同步;
　　(7) 照瓶電眼：檢測是否有瓶子通過，當有瓶子經過時輸出訊號使切刀開始旋轉，左右位置可以調整;
　　(8) 輸送帶：使用變頻器調整輸送帶速度，以適用于各產能的速度匹配;
　　(9) 帶瓶組：采用兩側同步傳動，標簽高低與夾瓶定位各一只手輪調整，目的使瓶子輸送時不搖晃和控制套標簽高度，速度由變頻器控制，與輸送帶同步。
　　2.2 套標機工藝流程
　　當輸送帶上有瓶子經過照瓶電眼時，由伺服控制的切標電機會將標簽切斷，切標完成后下標伺服電機開始動作，等到光纖信號到來時停止送標，同時刷下料輪會將已經切斷的標簽刷下套入瓶子上，完成一次動作。具體工藝流程如圖 2 所示。
硬件系統設計
　　3.1 硬件系統分析
　　本系統需要兩路高速脈沖輸出，分別控制切刀和下料伺服;一路高速計數器，用于控制切刀停止的位置，切刀停止位置應不影響下標的動作，否則會造成堵標。
　　以往套標機的調速方式普遍采用電位器控制，用三個電位器分別控制輸送帶電機，定位皮帶電機和螺桿電機，供料電機的速度因為不經常調節，所以用變頻器本身自帶的電位器調速。每次輸送帶速度變更時，都需要重新調節螺桿和定位皮帶的速度。調節時主要依靠調試人員的技術經驗和不斷的放瓶測試，才能使其線速度基本同步。本項目中設備的 I/O 清單如表 1 所示。
　　3.2 硬件系統設計
　　在本項目的電控方案中，選用西門子 SMART 解決方案，包括 S7-200 SMART PLC、SMART LINE 觸摸屏和 SINAMICS V20 變頻器。根據上述 I/O 需求，總共 12DI/12DO，選用 CPU ST40(24DI/16DO) 即可滿足需求。 SINAMICS V20 變頻器通過 USS 協議與 PLC 進行通訊，不僅控制更加方便，也節省了 PLC 的 I/O 點。通過計算可將電機角速度轉化為輸送帶線速度。PLC 和觸摸屏通過以太網進行通訊，只需要在觸摸屏上輸入生產速度，其他電機將會自動進行線速度同步。該方案大大縮短調試時間，降低調試難度。硬件結構如圖 3 所示，主要硬件配置表如表 2 所示。
4 軟件系統設計
　　4.1 運動控制配置
　　S7-200 SMART 集成了三路 100kHz 的高速脈沖輸出，在本系統中切刀伺服占用 Q0.0，下標伺服占用 Q0.1。打開 Micro/WIN SMART 集成的運動控制向導，配置軸 1 和軸 2，選擇單向相對脈沖，最大速度 50K，最小速度 1K，加減速時間 30ms，然后生成子程序。
　　4.2 高速計數配置
　　S7-200 SMART 集成了 4 路高速計數器，在本系統中只使用了高速計數器 HSC0，用于接收切刀的脈沖輸出，占用輸入點 I0.0。打開 Micro/WIN SMART 集成的 HSC 向導，配置 HSC0，選擇工作模式 0，預設值為 80000，當前值為 0，計數方向向上，勾選 PV=CV 時中斷，步數 1，然后生成。當切刀伺服啟動后檢測到刀盤原點光電時，利用外部中斷快速更新高速計數器 HSC0 的當前值和目標值，目標值等于當前值加上偏置值。PV=CV 中斷時停止脈沖輸出，同時啟動下標伺服。
　　4.3 USS 通訊
　　S7-200 SMART 自帶庫文件 USS 協議，只需調用 USS 功能塊即可實現 PLC 與西門子變頻器的通訊。通過 USS_INIT 進行通訊參數初始化設置，包括與變頻器通訊的波特率，激活的變頻器個數，所占用的端口等，通信參數必須與變頻器設置的一致，否則無法通訊。每次通信參數的更改都需要重新執行此命令，本項目中的通訊參數固定，所以只上電執行一次。通過調用 USS_ CTRL 指令可以直接控制變頻器的啟動、停止以及頻率，每條 USS_CTRL 指令只能控制一臺變頻器。
　　4.4 SINAMICS V20 變頻器的配置
　　設置V20變頻器的連接宏為Cn010—USS控制，分別設置螺桿、皮帶、供料、輸送帶變頻器地址 P2011[0] 為 1、2、3、4。同時，設置應用宏為 AP030—傳送帶控制，SINAMICS V20 可自動配置適合傳送帶應用的控制參數。
 

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ATV-58HD12M2 5.5

USB-9421

6GK1541-2BA00

DPS-350NB-1

SUN 375-3536

PCISA-C400R-RS-R20

TPC-1261H-A1E

1492-SPM1B030-N MCB Supplementary Protector 3 A

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GA647IFSTRNUNLMT GCA iFIX Std HMI Unlmt Run

GP647IFPLSR00150 GCP iFIX Plus SCADA 150 I/O Srv

IC600BF942RR -10Vdc to +10Vdc Analog Output Module (4 channels)

IC647HSTCR50KM Collector Redundancy Option for Historian - Standard Server 50000 Points (M4 Key)

IC647TPR935 CIMPLICITY HMI ProServer 35,000 I/O Runtime System

IC693PTM100CA Conformal Coated Power Transducer Module

IC756MDV001J-97 DV Development - Alpha OpenVMS Addt'l User, Japanese, Version 9.7

MicroLogix 1000/1761 System 1761-NET-DNI DEVICENET INTERFACE (DNI)

PLC-5/1771 System 1771-NBTC HIGH RESOLUTION ISOLATED ANALOG MODULE

Distributed I/O 1792D-CB18 MAXUM ROUND MEDIA 18MM BASE, PASSTHRU FOR DNET

Communications 9351-HPUS INTERCHANGE FOR HP-UX

Operator Interface D6190-6.5.24 CONTROLVIEW GETTING STARTED

Support 9356-STD2400S SUPT RENEWAL CONTRACT FOR 9356STD2400

Support 9392-CDRSFRE DATADISC ENGLISH/FRENCH BUNDLE

RSI Software Products 9323-L2300DU UPGRADE: IN-SUPT: 6200-2 BOTH TO AI-2 BOTH

RSI Software Products 9301-2SE3500KOU5 RSVIEW32 RUNTIME 5K-100K UPGRADE IN-SUPT (KO)

RSI Software Products 9356-SQLSAPADENE RSSQL FOR SAP SOLUTIONS ADDITIONAL SAP MODULE

Motion Control TL-A230P-BJ32AA MOTOR, SERVO, 1.3NM, 5000RPM, 17BIT SERIAL FEEDBAC

44A738935-001 Cable, Motion Mate MCS300 Series Interface Cable

IC200CHS002 I/O CARRIER BOX STYLE

IC694MDL340 OUTPUT MODULE 120 VAC 0.5AMPS 16 POINTS

MSI-UNIV-WEB-25 Universal Web Client(RTIP / Dashboard / Web / Excel Addin) 25 Pak

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20BD040A0AYNANC0 PowerFlex 700 AC Drive 40 A at 30 Hp 20B

20G11JC1K1JN0NNNNN PowerFlex 755 AC Packaged Drive

22D-D010N104 PowerFlex 40P- 4 kW (5 HP) AC Drive

140NOE77101 Quantum TSX QUANTUM ETHERNET 10/100 BASE T100FX

290D-FBZ-G2 Direct Online Starter

E53-AZ01 NEW RS232通訊板

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PXIe-2569

AVCLAN PS10311 PC113-A

C79298-A3238-B903

MIO-AUDIO 888

D1280E1-PCI

Q80BD-J71LP21-25

1492-N901 TERM BLCK Marking Cards for HM

安裝導軌 6ES7390-1AJ30-0AA0 安裝導軌，830 mm