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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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Motion Control MPL-B860D-MJ24AA MOTOR,SERVO,63.0NM,2000RPM,MULTI,460V,BRKE

Silver Series 1398-DDM-005X-DN DRIVE,7.5A PEAK, ULTRA 100 W/DNET INDEX

HE300RSL130 P1 interface for AF300E$ drives

IC646TDV915 1,500 I/O Point Development System

QBH2D100S2P QUICKPANEL 6" STN HAND HELD BUNDLE

ST-2792 STXi output module Relay Output 2 points, 230V AC/ 2A, Manual

20BC105A0AYNACD0 PowerFlex 700 AC Drive 20B

20F14NC205JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-B1P5H204 PowerFlex 4 0.2 kW (0.25 Hp) AC Drive

284D-FHD1P4Z-10-CR-SB DeviceNet Variable Frequency Drive

CJ1H-CPU66H CPU單元I/O點數2560，120K程序容量，最多三個擴展機架。

PCL-10168 68-pin SCSI-II電纜，1M,2M

PCI-MIO-16XE-10

845GV P4I845GVE-L

PCA-6166

contec MB-PCI3/3(PC) PCI-ISA

BPP-P2I6

R1S2-5300V4V

1492-M6X10V101-200 Connection Products

1494HL-EN3H2 General Duty Safety Switch

軟啟動器 3RW44466BC36

CA-860-2 LMI Adapter to GP-3102NT GagePort.

GC647SDL001 GCScheduler Doublet license for PC user

IC200PKG101 I/O starter kits, Genius NIU

IC646TBAPC002 Back-up Server for Advanced Process Control

IC647NCL000 CIMPLICITY HMI Action Calendar Option

IC690CBL710 CIMPLICITY 70 RGB Video Cable

IC697VSC096 Single Board Computer, with 32Mbyte SDRAM & 96 Mbyte Flash. NO OPERAT ING SYSTEM PRE LOADED

IC800VMA012 100 W VersaMotion servo amplifier

SLC/1746 System 1746-C16 CHASSIS INTERCONNECT CABLE, 4FT (1.22M)

Industrial Computers 6181P-17TPXPH VERSAVIEW INTEGRATED DISPLAY COMPUTER 17-INCH TFT

Application-specific products 9358-PBPC10ENE RSBIZWARE BATCH FOR PLX PC BASED PHASE 10 UNITS

Operator Interface 2711-K5A3 PV550 MONOCHROME KEY, DH485 & RS232 PRINT

Support 9301-2SE2100JPS SUPT RENEWAL CONTRACT FOR 93012SE2100JP

Support 9500-CPAKPMENR SUPT REINSTATEMENT CONTRACT FOR 9500CPAKPMEN

ControlNet Products 2711P-RN15S CONTROLNET COMMUNICATIONS MODULE

RSI Software Products 9301-2SE2503ESE RSVIEW32 WORKS 100K WITH RSLINX (SPANISH)

RSI Software Products 9358-BEPNT60ENE EPROCEDURE FOR NT 60 UNITS

Motion Control MPL-A520K-SJ24AA MOTOR,SERVO,10.7 NM,4000RPM,SINGL,230V,BRK,13.9KG

Motion Control 2090-XXNPMP-14S20 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,14 GAUGE,20M

GABK3D200C2P/SR QUICKPANEL 6" TFT W/SER GE LABEL

IC641SWM313 Logicmaster 90-30 TCP/IP-Ethernet, Cable & Paper Manuals