PLC控制系统 英文文献+翻译
Beer filling, Gland machine PLC control system 1.Intorduction
Malt beer production process is divided into manufacturing, manufacturing wort, before fermentation, after fermentation, filtration sterilization, packaging, and so few procedures. Beer filling, Gland part of a packaging machine processes. The membrane filtration of beer after the pipeline into the rotary Jiugang, then the valve into the bottle of wine, Gland, was bottled beer. Beer filling, Gland machine's efficiency and degree of automation direct impact on the level of beer production.
China's beer industry to meet the increasing scale of production and the demand for beer modern high-speed filling machinery filling the requirements of domestic beer manufacturers are actively seeking to transform the unit or the filling of beer production equipment, making it a good use Performance, advanced technology and high production efficiency and operating a safe and secure, low maintenance costs of the modernization of beer filling machine. 2. Filling beer, Gland principle and control aircraft parts
Liquid filling machine by filling principle can be divided into atmospheric filler,filling machines and vacuum pressure on the filling machine. Beer filling,Gland-filling method used pressure is higher than the atmospheric pressure under the filling, storage of the cylinder pressure than the pressure of the bottle, beer bottle into the liquid on pressure.
Technology at home and abroad to achieve the filling line is basically: The Rotary Jiugang the rotating movement, placed in Jiugang slots on the empty bottles through the machinery will be fixed at the upper Jiugang vacuum valve to open, closed Vacuum bottles for good treatment, Bozhuan stem from operating, open the valve of the bottle filling CO2 gases, vacuum convex .Round to open the vacuum valve, the bottle will air mixed with CO2 out of gas, open the valve again, the CO2 gas bottle filling, the filling valve on the pressure valve in the bottle close to back-pressure gas pressure at the open-Jiuye Pingbi into the bottle, through pneumatic or electrical control filling valve to achieve the filling of beer.
Today's advanced international beer filling, Gland machine control system mainly by the photoelectric switch position detection part and take the bottles with, Jiugang speed part, dominated by the PLC, touch screen and other components. Filling, Gland of the mechanical structure and PLC programmable control devices, frequency stepless speed regulation, human-computer interface, and other modern means of complete automatic control technology, the combination of a mechanical and electrical integration.
3. Controlled part of the programme
Many domestic beer manufacturers are now using the filling, Gland of the control system of uneven degree of automation; button and all the manual switch technology have set up operations in a box on the panel, PLC controller for the majority of Japanese companies or OMRON Mitsubishi's early products, equipment chain of control, less protection settings, plus the beer filling the scene poor environment, humidity, such as contact with the switch contacts serious corrosion, the system's signal detection of the high failure rate, resulting in equipment control system Operation of low reliability, the normal operation of equipment, such as short-cycle phenomenon.
To the actual transformation of the Dandong Yalu River Brewery Co., Ltd. of filling, Gland machine control system as an example, the transformation of methods to clarify the control of such equipment thinking and ideas, according to the scene of the actual process conditions, to prepare the operation of the PLC Procedures. For beer filling, Gland control system of the actual situation and in accordance with the actual process conditions at the scene, re-design of the equipment of the PLC control system. This transformation of the same methods and ideas can be applied to other liquids and the transformation of filling equipment. 3.1 system hardware configuration
Japan's Mitsubishi Corporation to use the FX2N128MRPLC use the system to replace the original 2-OMRON's C60P PLC, the original system of the PLC is due to old models, and computer on-line communications need to configure special converters, the system need to increase the external I / O input points , The extension of spare parts more difficult to find. FX2N128MRPLC is an integrated 128-point I / O controller of the box, a computing speed, command rich, high-cost performance, on-line programming simple and easy extension of the advantages of the Mitsubishi FX series, features the strongest small controller .
(1) by the Mitsubishi 900 series of 970 GOT human-computer touch screen system to replace the original use of the button panel display equipment and monitor the operation of operating parameters. 970GOT HMI for the 16-color high-brightness significantly, through the convergence of connectivity and FX2N128MRPLC directly connected to the CPU, achieving rapid response. Has many maintenance features, such as the list-editing features, ladder monitoring (troubleshooting) function, the system monitoring functions to find fault and maintenance of PLC Systems.
(2) filling, Gland of the frequency converter in the transformation of no replacement, on-site detection signal means-testing is still used switch, switch for detecting long-term work in the humidity of the great occasions, the choice of capacitive proximity switches, according to PLC I / O terminal of the connection mode, select the type of close PNP switch, the control system of Figure 1. 3.2 Systems Programming
PLC controller programming focus and the core is around Jiugang the rotation speed control and Jiugang on 60 bottles of detecting the location of the displaced, broken bottles, empty bottles at the location of testing and related displacement filling Such as control valves. The bottles displacement of testing procedures, using a Mitsubishi PLC in the left command.Figure 1 control system structure diagram .
Bottles displacement of detection, using the left-PLC command, which commands the whole of one of the core control procedures, the main electrical switch detection and bottles at the bottle simultaneously detect mobile, the main motor to every week, just to the corresponding Jiugang Have a bottle of, PLC unit within the internal correspondence that 60 bottles of the unit for the M500 ~ M559, the number of units by the first letter K is set to K60, with each change in a second letter K is set to K1, M50 Reaction of the empty bottles in the short position, and detect the location of the motor speed to go on the frequency shift in the corresponding unit within the built-in "1" or "0", control valves and the corresponding mixing caps The motor stopped and opened. Continuous detection system in place after the 90 empty bottles, stop stirring caps the motor running, testing the number of bottles in accordance with the user's requirements can be arbitrary.
A bottle of detection. Rotary Jiugang through pressure to back pressure with the bottle of liquor in the process of empty bottles in the back-pressure, because the bottle itself may crack and other reasons leading to a sudden burst bottles, which need to detect the location of unexploded bottle bottle, in this bottle - The position opened purge solenoid valves, compressed air out, broken bottles at the bottle-blowing from the position in a row after the purge and several bottles of the electromagnetic valve open jet, a high-pressure spray Shuizhu, in the break Bottle position around a few bottles of spray bottles in a row.
Detection of broken bottles and bottle-detection switch simultaneously detect movement of breaking bottles, to the main motor of each week, precisely corresponding Jiugang passed a bottle of, PLC unit within the internal correspondence that 20 broken bottles at the unit for the M600 ~ M619, unit With the number of the first letter K is set to K20, with each change in a second letter K is set to K1, M52 response to the location of the broken bottles and detected the location of the motor speed to the frequency shift continue, In the corresponding unit within the built-in "1" or "0", control and the corresponding jet purge solenoid valve opened and stopped. Continuous Spray and purge solenoid valve open to listen, time stopped in accordance with technological requirements can be arbitrary.
System security is to control access to the caps simultaneously tracking, not only accurately detect the electrical switching speed detection, the broken bottles into the bottle and detection switch detection switch three conditions.
970GOT human-computer touch-screen terminals operated by the software company's Mitsubishi GT WORKS package, which is a GT Designer with the entire GOT9000 series of graphics software packages. The package is simple, prior to a personal computer simulation on the configuration and debug, after the man-machine operators to download terminals. At the same time, because the man-machine interface and a touch-screen role, will set common switch on the screen to facilitate the operation. And also to increase the number of features, such as setting alarm information. 4.After transformation control system
System at the normal operation of the machine for automatic control, in accordance with bottles into and out of the bottle for lack or slow pace set by running into the bottle stall bottles, no less than a bottle cap, automatic washing bottles burst, filling automatic back-pressure position , Covered under the system automatically lose covered a stop and safety protection, such as the coordination of action interlock. All the original button after the operation of the touch screen on. 5.Detection of the state control system monitoring
Detection switch into the bottle and break bottles detection switch bottles of pressure by testing each part of the small metal plates above the location of a photoelectric pulse output, a further PLC acquisition, as each bottle of the pressure above the small metal plates is the location of activities , In the machine running after some time, some pressure above the small bottles of iron tablets and detection switch in the location of displacement, resulting in detection switch mistaken judgement, if not for the judgement of bottles of bottles, bottle explosion Lou Jian, misuse, such as the seizure of output errors So that the PLC have mistaken action, such as a back-pressure, unexploded bottle blowing, washing, stirring cap control system malfunction, such as failure phenomenon.
Before the transformation of the daily production process, encountered this phenomenon, the operatives could only switch to the various functional or manual control buttons reach the stall so that the equipment work in the absence of monitoring state, the machine lost control function. Caused a lot of production of raw materials such as gas, water, wine waste. Only in the production of intermittent, can be fitter and maintenance electrician in accordance with the detection of small switch on the light-emitting diodes and anti-displacement by adjusting the distance only 5 ~ 8 mm detection switch installation location, and switch to fix detection of small metal plates Gap. This means of detection is very backward, after adjustment reaction to the results, timely response can not be adjusted results.
In view of this testing situation, after the transformation of the filling, Gland control system configuration, this part of a new detection and integration in human-computer touch screen, complete bottle of detection.
In human-computer touch screen interface on the page display, respectively, at customs, such as electromagnetic motor mixing valve switch state are in different colors to show, very intuitive.
Increase the system's functions is to ensure the irrigation of the machine-Gland normal operation of automated control system specifically designed to. 6 Concluding remarks
After the transformation of the control system will greatly simplify the complicated mechanical structure, the running and control of inspection, the degree of automation systems meet the design requirements, greatly reducing the operational strength of the labor so that the shrub-like beer output than in the past Raising more than 30 percent, greatly reduce the failure rate. Embodies the modern equipment of automatic control technology. In the digestion and absorption of today's industrial control on the basis of advanced technology innovation, development of domestic technology from the most advanced filling control system.
啤酒灌装、压盖机PLC控制系统
1、引言
啤酒生产过程分为麦芽制造、麦芽汁制造、前发酵、后发酵、过滤灭菌、包装等几道工序。啤酒灌装、压盖机部分属于包装工序。啤酒经膜过滤后由管路送入回转酒缸，再经酒阀进入瓶子中，压盖后获得瓶装啤酒。啤酒灌装、压盖机的工作效率和自动化程度的高低直接影响啤酒的日产量。
为了满足我国啤酒行业日益扩大生产规模的需求和啤酒现代化灌装机械高速灌装的要求，国内各啤酒生产厂家都在积极寻求或改造本单位的啤酒灌装生产设备，使其成为具有良好的使用性能，先进的技术水平及高生产效率、运行稳妥可靠、维护成本低的啤酒现代化灌装机。
2、啤酒灌装、压盖机工作原理和控制部分构成
液体灌装机按灌装原理可分为常压灌装机、压力灌装机和真空灌装机。啤酒灌装、压盖机采用压力灌装方法，是在高于大气压力下进行灌装，贮液缸内的压力高于瓶中的压力，啤酒液体靠压差流入瓶内。
目前国内外实现灌装工艺路线基本上是：利用回转酒缸产生的旋转运动，使安放在酒缸槽位上的空瓶通过机械机构将固定在酒缸上部的欲抽真空阀打开，对已封好的瓶子进行抽真空处理，拨转外操作阀杆，打开气阀，对瓶内充填CO2气体，抽真空凸轮继续打开真空阀，将瓶内空气与CO2混合气体抽出，气阀再次打开，对瓶内充填CO2气体，灌装阀内的液阀在瓶内压力接近背压气体压力时打开，酒液顺瓶壁注入瓶内，通过气动或电动控制灌装阀实现啤酒的灌装。
当今国际先进的啤酒灌装、压盖机的控制系统主要由光电开关位置检测部分、走瓶带、酒缸转速的变频调速部分、主控由可编程控制器、触摸屏等组成。灌装、压盖机的机械结构装置与PLC可编程控制、变频无级调速、人机界面等现代自动控制技术手段完整的结合，形成机电一体化。
3、控制部分改造方案
国内很多啤酒厂家现使用的灌装、压盖机的控制系统的自动化程度参差不齐；所有手动按钮和工艺开关都设置在一个操作箱的面板上，PLC控制器大都为日本OMRON公司或三菱公司的早期产品，设备连锁控制、保护设置少，加之啤酒灌装的现场环境恶劣，潮湿度大，使开关等接触触点锈蚀严重，系统的信号检测部分故障率较高，造成设备控制系统运行的可靠性低，设备正常运行周期短等现象。
以实际改造的丹东鸭绿江啤酒有限公司的灌装、压盖机的控制系统为例，介绍改造方法，阐明改造这类设备的控制思想和思路；根据现场的实际工艺条件，重新编写了PLC的运行程序。针对啤酒灌装、压盖机控制系统的实际状况，并根据现场的实际工艺条件，重新设计了设备的PLC控制系统。这种改造方法和思路同样可以应用与其他液体介质灌装设备的改造。
3.1系统硬件配置
使用日本三菱公司的FX2N128MRPLC替换原系统使用的'2台OMRON公司的C60P PLC，原系统的PLC由于是老型号产品，和计算机联机需要配置特殊的通讯转换器，系统需要增加外部I/O输入点时，扩展模块备件较难寻。FX2N128MRPLC是集成128点I/O的箱体式控制器，具有运算速度快，指令丰富、性能价格比高、联机编程简单、扩展方便等优点，是三菱FX系列中功能最强的小型控制器。
(1)采用三菱公司的900系列的970GOT人机触摸屏替换原系统使用的面板按钮并监控显示设备的运行工作参数。970GOT HMI为高亮度的16色显，通过汇流连接和FX2N128MRPLC的CPU直接连接，实现快速回应。具有许多维护功能，如列表式编辑功能、梯形图监控(故障查找)功能、系统监控功能等用来查找故障和维护PLC系统。
(2)灌装、压盖机的变频器在改造中没有更换，现场检测信号的手段仍然采用开关式检测，因检测开关长期工作在湿度很大的场合，因此选择电容式的接近开关，根据PLC I/O端子的接线方式，选择PNP型的接近开关。 3、2、系统程序设计
PLC控制器的程序设计重点和核心是围绕着酒缸的旋转速度控制和酒缸上60个瓶位相关位置的检测移位、破瓶、空瓶瓶位相关位置的检测移位和相关灌装阀等的控制。其中的瓶位移位检测程序中，采用了三菱PLC位左移指令。
瓶位移位检测，采用PLC位左移指令，这条指令是整个子控制程序的核心之一，主电机和瓶位检测开关同步检测移动的酒瓶，主电机每转一周，正好对应酒缸转过一个瓶位，PLC内部单元内对应这60个瓶位的单元为M500~M559，单元个数用第一个字母K设置为K60，每次变化一位用第二个字母K设置为K1，M50反应了瓶位的空、缺位置，并将检测到的这个位置以电机转速的频率移位下去，在内部相应的单元内置"1"或"0"，控制相应的阀门和搅拌瓶盖的电机的开与停。系统在连续检测90个空瓶位后,停止搅拌瓶盖的电机的运行,检测瓶位的个数可以根据用户的要求任意设定。
出瓶位检测。回转酒缸通过压力往瓶内背压装酒的过程中，空瓶在背压后,可能由于瓶子本身裂纹等原因导致突然爆瓶,这就需要检测出爆瓶瓶子的位置,在这个瓶位的位置进行打开吹扫电磁阀,喷出压缩空气,将瓶位上的碎瓶片吹离位置,在连续吹扫几个瓶位后,在打开喷射电磁阀,喷射出高压水注,在对破瓶位置周围瓶位连续喷射几个瓶位。
破瓶检测和瓶位检测开关同步检测移动的破瓶，主电机每转一周，正好对应酒缸转过一个瓶位，PLC内部单元内对应这20个破瓶位的单元为M600~M619，单元个数用第一个字母K设置为K20，每次变化一位用第二个字母K设置为K1，M52反应了破瓶的位置，并将检测到的这个位置以电机转速的频率移位下去，在内部相应的单元内置"1"或"0"，控制相应的喷射和吹扫电磁阀开与停。连续喷射和吹扫电磁阀的开听、停时间可以根据工艺要求任意设定。
系统自动化运行可靠的保障就是控制进出瓶盖的同步跟踪，既准确检测电机转速检测开关、破瓶检测开关和进瓶检测开关三个条件。
970GOT人机触摸屏操作终端机的软件采用三菱公司的GT WORKS软件包，其中GT Designer是一个用与整个GOT9000系列的绘图套装软件。该软件包操作简单，事先可在个人计算机上组态并仿真调试，完毕后下载至人机操作终端机。同时，因为人机界面又具有触摸屏的作用，将常用的开关设在显示屏上，方便操作。还可并以增加一些功能，如设置报警信息等。
4、改造后控制系统功能
系统正常运行时，机器为自动控制，根据进出瓶带上瓶的满缺，按设定速度或慢速运行，进瓶档瓶，无瓶不下盖，爆瓶自动冲洗，灌装位置自动背压，下盖输盖系统的自动开停和安全保护等动作的协调联锁。原来所有按钮的操作改造后都在触摸屏上进行。
5、控制系统检测状态的监控功能
进瓶检测开关和破瓶检测开关通过检测每个压瓶部分上面的小铁片的位置，产生光电脉冲输出，再有PLC采集，由于每个压瓶部分上面的小铁片的位置是活动的，在机器运行一段时间后，压瓶部分上面的小铁片和检测开关的位置发生位移，造成检测开关误判断，如没瓶判断为有瓶，爆瓶漏检、误检等造成输出失误，使PLC产生误动作，造成如背压、爆瓶吹、洗、瓶盖搅拌系统控制失灵等故障现象。
在改造前的日常生产过程中，碰到这种现象时，操作工只能将各个功能开关或按扭打到手动控制档位，使机器设备工作在无监控状态下，机器失去自动控制功能。造成了很大的生产原料如气、水、酒的浪费。只能在生产的间歇，才能由维修钳工和电工根据检测开关上的小发光二极管的亮和灭通过调整位移距离只有5~8mm的检测开关的安装位置，来修正检测开关和小铁片的间隙。这种检测手段非常落后，调整后的效果反应致后，不能及时反应调整结果。
针对这种检测状况，结合改造后的灌装、压盖机控制系统的配置，新增了这部分检测功能，并集成在人机触摸屏中，完成瓶位检测。
在人机触摸屏的界面分页显示屏上，可以分别时关、搅拌电机等电磁阀的开关状态都以不同颜色来显示，非常直观。
增加这套系统功能的是为保证灌状压盖机的自动化控制系统正常运行而专门设计的。
6、结束语
改造后的控制系统大大地简化了复杂的机械结构，经现场运行情况和控制效果检验，系统的自动化程度达到了设计要求，大大减少了操作人员的劳动强度，使啤酒灌状的日产量比过去提高30%以上，故障率大大减低。体现了现代设备的自动控制技术。是在消化、吸收当今工业控制的先进技术的基础上加以创新、研制而成的目前国内技术最先进的灌装控制系统。
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