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1、 包装自动化输送线智能控制系统研制 广东工业大学硕士学位论文 (工程硕士） 包装自动化输送线智能控制系统研制 黄景 指导教师姓名、职称： 刘伟副教授 学科 (专业 )或领域名称： 材料工程 学 生 所 属 学 院 ： 材 料 与 能 源 学 院 论文 答 辩 日 期 ： 2016年 6 月 3 日分类号 : UDC： 密级 : 学校代号： 11845 学号： 2431302735 A Dissertation Submitted to Guangdong University of Technology for the Degree of Master (Master of Engineeri
2、ng ) Research on intelligent control system for packaging automat transmission line Candidate: Huang Jing Supervisor: Liu Wei May 2016 School of Electromechanical Engineering Guangdong University of Technology Guangzhou, Guangdong, P. R. China, 510006 摘要 在现代化制造企业中，自动化生产线被广泛使用，大大地提高了产品的生产效 率。一致的标准化生产
3、也使得产品的品质更加可控。可是它主要是实现了生产过程 中产品相关零部件的制造或者组装自动化的完成。而在原材料由仓库进入制造设备， 再将由其制作出的零部件等运送到装配线，再由装配后的半成品运送到成品组装线， 再将成品输送到打包线以及将包装好的产品运送到仓库堆码存放的过程基本上是由 人类完成，这直接导致整个生产由于 输送环节制约了生产的效率，同时大量人力物 力的参与，也使得企业制造成本增加。而本课题中的自动化输送线正是运用于衔接 各式各样的自动化生产线，透过生产协同让效率大幅度提高，同时也减少人工参与 的可能，继而保证产品在运送的过程避免人为的二次污染包装产品的优良率。本文 设计的自动化输送线主要
4、是完成将产品从材料到成品包装的自动生产线衔接成一个 整体，使企业从制造自动化向工厂自动化转变，大大提高企业的综合竞争能力。 .本文的设计方案是在通过阅读大量的相关文献以及与企业主责生产的工程师、 一线员工、企业负责人等进行详细探讨后针对食品、五金等产品获得的。在生产领 域里，特别是一些产品附加值低、生产量又非常巨大的企业，往往在运输环节需要 投入大量的人力，同时人工成本的不断提高，又导致企业负担越来越大。所以企业 迫切需要一种能衔接各种生产线的设备来代替人力成本。我们主要是选用了 PLC与 人机界面的搭配，利用变频器与伺服器来控制电机拖动皮带输送的方式进行设计， 然后配合光电开关、光电编码器等
5、传感器收集信息，再通过逻辑处理驱动相 关元器 件执行预定动作，从而实现产品按照生产需要进行智能化输送。在实践中发现，这 种小而精的方案最适合这类企业的需要，无需大量的投入同时解决了企业自身的实 际需求。 在设计中，为了保障输送线的控制要求，采用了台达公司的 PLC和维纶通的人 机界面。两者的结合，让操作人员能够便捷的操控整个生产流程。随时监控生产环 节而且能够随时根据生产线的生产参数进行相应设置， .从而保障了连续化生产的进 行。为了实现以上的效果，我们对输送线的机械机构进行了相应设计，同时对 PLC 以及人机界面进行了相关的程序编写和界面规划。在多 次的实验、试产的过程中， 同时针对反馈情况
6、进行了相关的修正，最终完成了整套系统的设计。 在建立好输送线硬件与软件的基础上，我们通过人工投料实验、企业试生产调试 和企业正式大批量生产运用进行多次论证，然后总结其中的经验，对变频器、伺服 器的参数进行修正，最终验证了采用本套控制系统后，在同等产能要求下，包装设 备数量减半，人工由原来的 64人缩减到 18人，废品率降低 10倍，所以新的生产模 式具备可行性，完全满足企业的生产要求。 关键词：输送线 ； 智能 ； PLC ;人机界面 ABSTRACT In the modem manufacturing enterprise, the automatic production line is
7、 widely used, which greatly improves the production efficiency of the product. Consistent standardized production also makes the quality of product more controllable. But it is mainly to realize the production process of product related to parts manufacturing or assembly automation complete. And in
8、the raw material from the warehouse into manufacturing equipment, then by its produce parts transported to assembly line, by assembling semi-finished products transported to the finished product assembly line, then the finished product is delivered to the packing line and packaging products transpor
9、ted to storage warehouse stacking process is basically done by humans, which led directly to the entire production due to transport factors restrict the production efficiency, also participate in a lot of manpower and material resources, but also makes manufacturing cost of the enterprise be increas
10、ed. And the subject of automated conveyor line is used to connect all kinds of automatic production line, lets efficiency has been greatly improved by means of production synergy and the artificial be reduced to participate, then ensure the products in the transport process to avoid man-made seconda
11、ry pollution of packaging products and excellent rate. In this paper, the design of automated conveyor line is mainly completed products from materials to finished packaging automatic production line is connected into a whole, so that enterprises from automated manufacturing shift to factory automat
12、ion, greatly enhance the comprehensive competitive ability of the enterprise. In this paper, the design of the program is to read a large number of relevant literature and the companys main responsibility for the production of engineers, first line staff, the company responsible for the detailed dis
13、cussion of the food, hardware and other products obtained. In the field of production, especially the added of value some product is low, the production volume and very great enterprise, often in the transport links need to put in a lot of manpower. Meanwhile, the increase of the labor cost lead to
14、the burden on enterprises more and more. So the enterprise urgently needs a kind of equipment that can connect all kinds of production line to replace the labor cost. We mainly use PLC and man-machine interface collocation, the use of frequency converter and the server to control the motor drive bel
15、t transmission design, and then with photoelectric switch, photoelectric encoder sensor to collect information, through the logic driven processing components perform a predetermined action, so as to realize the product according to the production of intelligent transportation needs. In practice., i
16、t is found that this small and refined scheme is most suitable for the needs of such enterprises, without a lot of investment to solve the actual needs of the enterprise itself at the same time. In order to ensure the control of transmission line, the Deltas PLC and Vinylon through man-machine inter
17、face is used in the design. Through the combination of the two， the operator can easily manipulate the entire production process. Monitoring the production process at any time is able to set up the production parameters according to the parameters of the production line at any time, thus ensuring th
18、e continuous production. In order to attain the above results, the corresponding design of the mechanical structure of the conveyor line, and the PLC and the man-machine interface of the relevant procedures for the preparation and interface planning is carried out. In several experiments, the trial
19、production process, also for feedback were modified, finally completed the design of the whole system. On the basis of a well-established hardware and software of conveyor line, many real experiments are made through artificial feeding experiment, and enterprise test debug and production enterprises
20、 in the formal large batch production* Then the parameters of frequency converter and the server are revised by means of the summary of the experiments Finally, used this control system, in the same capacity requirements, the number of the packaging equipment reduced to half, artificial demand numbe
21、r reduced from the original 64 to 18 people, scrap rate reduced by 10 times. Thus, the control system is feasible, and fully meets the requirements of enterprise production. Key words： Transmission line; Intelligence; PLC; HMI 摘要 . I ABSTRACT . Ill M . v CONTENTS . VIII m-m . i 1.1课题的研宄背景及意义 . i 1.2
22、课题的来源与研宄内容 . 2 7.2./本课题来源 . 2 1.2.2主要研宂内容 . 2 1.3包装自动化输送线的国内外研究状况 . 3 1.3.1国外包装自动化输送线研宄状况 . 3 1.3.2国内包装自动化输送线发展状况 . 4 1.4自动化输送线控制系统发展趋势 . 4 1.5包装自动化输送线基础理论 . 5 1.5.1自动化控制的理论 PID控制理论 . 5 1.5.2自动化控制的理论模糊控制理论 . 7 1.6本章小结 . 8 第二章包装自动化输送线硬件系统总体设计 . 9 2.1冷却线的自动化改造 . 10 2.1.1冷却线的皮带跑偏机构 . 11 2.1.2冷却线的集中控制设计
23、 . 12 2.2智能输送线的机械部分设计 . 13 2.2.1输送线主平台 . . 14 2.2.2排齐机构模块 . 15 2.2.3翻板下放机构 . 16 2.2.4收料台的机械设计 . 18 2.2_5传感器的选用 . 19 2.3本章小结 . 19 第三章包装自动化输送线电路及各功能模块的设计 . 20 3.1主电路设计 . 20 3.U输送线主电机的启停动作控制配线 . 20 3丄 2变频器的控制配线 . 21 3.2控制功能模块的配线 . 22 3.2.1输送平台 . 22 3.2.2收料平台和摆动机构 . 23 3.3控制系统电气硬件配置 . 24 3.3.1 PLC控制器的选择
24、 . 25 3.3.2变频器参数的设置 . 25 3. 4本章小结 . 26 第四章控制系统的编程和设置 . 27 4.1 PLC的编程设计 . 27 4.2 WPLSoft编程界面说明 . 27 4.3系统功能实现部分 PLC程序编写 . 29 4.3.1冷却线控制 . 29 4.3.2输送线主平台控制 . 33 4.3.3排齐机构的控制 . 36 4.3.4翻板下放机构的控制 . 37 4.3.5收料台控制 . 39 4.4人机界面的设计 . 40 4.4.1 组态软件 EB8000 Project 简介 . 40 4.4.2人机界面与 PLC连接的实现 . 41 4.4.3输送线人机界面
25、程序的设计 . 42 4.5本章小结 . 45 第五章智能包装输送线生产试验研究 . 46 5.1胚料张力控制对产品质量的影响 . 46 5.2产品状态对输送线输送效果的影响 . 465.2.1试产 f青况下的分析 . 46 5.2.2正式生产情况下的分析 . 47 5.3生产模式变更后对厂家的影响 . 49 总结与展望 . 51 参考文献 . 52 攻读学位期间发表的论文 . 54 学位论文独创性声明 . 55 学位论文版权使用授权声明 . 55 SC m . 56 vnCONTENTS ABSTRACT(Chinese) . I ABSTRACT(English) . Ill CONTEN
26、TS (Chinese) . V CONTENTS(English) . VIII Chapter 1 introduction . 1 1.1 The background of the subjec . 1 1.2 The source of the topic and research content . 2 1.2.1 The topic source . 2 1.2.2 Main Research Contents . 2 .3 Study status of automated conveyor line . 3 1.3.1 The research situation of ab
27、road automated conveyor line . 3 1.3.2 The research status of domestic automated conveyor line . 4 1.4 The development trend of automated conveyor line . 4 1.5 The basic theory of automated conveyor line . 5 1.5.1 The P1D control theory . 5 1.5.2 The fuzzy control theory . 7 1.6 Summary . 8 Chapter
28、2 The hardware system overall design conveyors line . 9 2.1 Cooling line automation reconstruction . 10 2.1.1 Cooling line belt running deviation of the organization . 11 2.1.2 The centralized control of cooling line design . 12 2.2 The mechanincal parts of the conveyor line design . 13 2.2.1 The ma
29、in platform . 14 2.2.2 Line organization . 15 2.2.3 Decenttalized organization . 16 2.2.4 Mechanical design in the receiving station. 18 2.2.5 The selection of the sensor . 192.3 Summary . 19 Chapter 3 the conveyor line circuit design . 20 3.1 The main circuit design . 20 3.1.1 Main motor start-stop
30、 control circuit . 20 3.1.2 Inverter control circuit . 21 3.2 The function module circuit . 22 3.2.1 Delivery platform circuit . 22 3.2.2 Mechanical parts circuit diagram . 23 3.3 Electrical hardware configurationg . 24 3.3.1 In the selection of PLC . 25 3.3.2 Inverter parameter settings . 25 3. 4Su
31、mmary . 26 Chapter 4 The preparation of the system program . 27 4.1 PLCprogramming design . 27 4*2 Programming interface specification for the WPLSoft . 27 4.3 System functiongal programming . 29 4.3.1 Cooling line control . 29 4.3.2 The main platform control . 33 4.3.3 The line control . 36 4.3.4 Devolved institutions control . * . 37 4.3.5 Receiving station control . 39 4.4 The man-machine interface design . .40 4.4.1 Programming software is introduced . 40 4.4.2How to connected PLC for the man-machine . 41 4.4.3Conteol interface design . 42 4.5 Summary .