自动配料装车的PLC控制系统设计

课程名称电气控制与PLC课题名称自动配料装车的PLC控制系统设计设计内容与要求一.课程设计的性质与目的本课程设计是自动化专业教学计划中不可缺少的一个综合性教学环节，是实现理论与实践相结合的重要手段。它的主要目的是培养学生综合运用本课程所学知识和技能去分析和解决本课程范围内的一般工程技术问题，建立正确的设计思想，掌握工程设计的一般程序和方法。通过课程设计使学生得到工程知识和工程技能的综合训练，获得应用本课程的知识和技术去解决工程实际问题的能力。二.课程设计的内容1.根据控制对象的用途、基本结构、运动形式、工艺过程、工作环境和控制要求，确定控制方案。2.绘制自动配料的PLC控制系统的电气原理图、控制系统的PLCI/O接线图和梯形图，写出指令程序清单。3.选择电器元件，列出电器元件明细表。4.上机调试程序。5.编写设计说明书三.课程设计的要求1.所选控制方案合理，所设计的控制系统能够满足控制对象的工艺要求，并且技术先进，安全可靠，操作方便。2.所绘制的设计图纸符合国家标准局颁布的GB4728－84《电气图用图形符号》、GB6988－87《电气制图》、GB7159－87《电气技术中的文字符号制定通则》。3.所编写的设计说明书应重点突出，层次清楚，条理分明，篇幅不少于7000字。主要设计条件1.实物PLC及其编程软件，PLC实验室设计说明书装订顺序1.课程设计说明书封面。2.课程设计任务书。3.说明书目录。4.正文（按设计内容逐项书写）。5.参考文献。6.附录。7.课程设计评分表。设计进度安排1.第一周星期一上午：课题内容介绍。2.第一周星期一下午：仔细阅读设计任务书，明确设计任务与要求，收集设计资料，准备设计工具。3.第一周星期二～第一周星期五：确定控制方案。绘制皮带运输机电气控制系统的电气原理图、控制系统的PLCI/O接线图和梯形图，写出指令程序清单。选择电器元件，列出电器元件明细表。4.第二周星期二：试验调试5.第二周星期三～第二周星期五：编写设计说明书,答辩。参考文献[1]刘星平.PLC原理及工程应用[M].北京：中国电力出版社[2]廖常初.PLC编程及应用[M].北京：机械工业出版社[3]万太福.可编程序控制器及其应用[M].重庆：重庆大学出版社[4]工厂常用电气设备手册编写组.工厂常用电气设备手册[M].北京：水利电力出版社[5]谢桂林.电力拖动与控制[M].北京：中国矿业大学出版社[6]刘星平.可编程控制器实验指导书.湖南工程学院附录：课题简介及控制要求有一个配料系统有四条传送带的传送系统，分别用四台电动机带动，控制要求如下：系统启动后，配料装置能自动识别货车到位情况及对货车进行自动配料，当车装满时，配料系统能自动关闭。1.初始状态系统启动后，红灯L2灭，绿灯L1亮，表明允许汽车开进装料。料斗出料口D2关闭，若传感器S1置为OFF（料斗中的物料不满），进料阀开启进料（D4亮）。当S1置为ON（料斗中的物料已满），则停止进料（D4灭）。电动机M1、M2、M3和M4均为OFF。2.装车控制当汽车开进装车位置时，限位开关SQ1置为ON，红灯信号灯L2亮，绿灯L1灭；同时启动电机M4，经过1S后，再启动M3，再经1S后启动M2，再经过1S最后启动M1，再经过1S后才打开出料阀（D2亮），料斗出料。当车装满时，限位开关SQ2为ON，料斗关闭，1S后M1停止，M2在M1停止1S后停止，M3在M2停止1S后停止，M4在M3停止1S后最后停止。同时红灯L2灭，绿灯L1亮，表明汽车可以开走。3.停机控制按下停止按钮SB2，自动配料装车的整个系统终止运行。试设计满足控制要求的PLC控制系统。实验面板图I前言可编程程序控制器（PLC,ProgrammableLogicController）因其高可靠性和较高的性价比，而在工业控制中被广泛应用。力控组态软件由于计算机的普及和其本身价值（实时多任务、开放性、灵活性、通用性和可靠性）的被认知，也在快速的发展中。本文基于可编程序控制器PLC和力控组态软件设计自动配料系统的控制系统和监控系统。首先，利用德国Siemens公司的S7-200系列PLC对自动配料系统进行控制。运用与之相配的STEP7编程，通过LAD编程语言编制了下位机的控制程序，从而使该配料系统可以按要求完成自动配料，装料全过程。其次，自动配料系统的监控系统则采用了力控组态软件对上位机监控软件组态，实现现场数据的实时监控。本文的主要内容包括对生产过程控制系统发展和现状的概述、配料系统工作原理和配料控制系统的总体设计，重点描述了包括硬件设计、编程环境及软件设计在内的西门子PLC在配料系统中应用的一些细节、组态软件及其在上位机监控系统中一些基本设计，以及PLC与上位机之间的通讯。关键词：可编程序控制器；配料；组态软件II目录前言·····································································································I第1章概述······················································································11.1可编程控制器的发展及前景······························································11.2可编程控制器的定义·······································································11.3可编程控制器的基本组成及功能························································21.4组态软件的发展·············································································2第2章任务简介及方案选择····································································32.1任务简介······················································································32.2方案选择······················································································42.3方案构思框架················································································52.4PLC型号的选择··············································································62.5监控软件的选择·············································································7第3章系统硬件设计·············································································93.1主电路设计···················································································93.2PLC的外部接线设计·······································································10第4章系统软件设计············································································124.1工作流程图以及顺序功能图的设计····················································124.2梯形图程序的设计·········································································164.3力控组态的设计············································································16第5章系统调试··················································································185.1下位机调试过程············································································185.2上位机力控调试过程······································································215.3故障分析解答···············································································23第6章总结························································································24谢辞·······································································································25参考文献·································································································26附录A·····································································································27电气信息学院课程设计评分表·······································································37湖南工程学院1第1章概述1.1可编程控制器的发展及前景1968年由美国通用汽车公司（GE）提出了研制可编程序控制器（即可编程控制器）的基本设想，希望尽量减少重新设计和更换继电器控制系统的硬件和接线，减少系统维护和升级时间，降低成本。希望将计算机的优点与继电器控制系统简单易懂、操作方便，价格便宜等优点相结合，设计一种通用的控制装置来满足生产需求。1969年由美国数字设备公司（DEC）研制成功世界上第一台可编程控制器，有逻辑运算、定时、计算功能，称为PLC（programmablelogiccontroller）。1980年后，由于计算机技术的发展，PLC采用通用微处理器为核心，功能扩展到各种算术运算，PLC运算过程控制并可与上位机通讯、实现远程控制。可编程控制器最初是用于替代继电器控制系统的新型控制器，现在的PLC功能更加完善，除了开关逻辑控制的场合能够大显身手外，在要求有模拟量闭环控制的场合，也不会比单片机孙色。单片机能够完成的工作PLC都能完成。而且PLC更适用工业生产现场环境，具有更高的可靠性及较好的电磁兼容性1.2可编程控制器的定义国际电工委员会（IEC）1985年颁布的可编程逻辑控制器的定