饮料灌装生产流水线程序设计与调试

机电工程学院课程设计说明书设计题目:饮料灌装生产流水线程序设计与调试学生姓名：学号：20094805专业班级：机制F09指导教师：2012年12月11日内容摘要社会的发展和进步对各行各业提出了越来越高的要求，硬连接方式的继电接触式控制系统不能满足经常更新的要求了，早期控制系统体积大、功能少，存在很多不足，PLC适应能力强，功能强大，可靠性高，抗干扰能力强，系统设计周期比较短等众多优点，应用越来与广泛。本次课程设计是饮料罐装生产流水线的控制系统设计程序设计，实现全自动灌装生产，当按下启动按钮时系统开始启动，光电传感器检测到瓶时实现自动灌装，定时器定时灌装时间，灌装结束后，传送带自动启动，直至光电传感器检测到下一个瓶，如此循环实现饮料的自动灌装，自动灌装的同时，用传感器感测，并用多个计数器记录下空瓶数、满瓶数和箱数，以便对生产的情况实时监控，提高生产效率，本次设计的思路运用并行结构，实行程序模块化，结构简单，清晰明了。关键词：自动循环；计数；模块1目录引言······································································································1第1章总体设计方案···············································································21.1系统设计程序的基本结构·····································································21.1.1系统控制结构图········································································21.1.2饮料灌装流水线的基本结构图······················································21.2灌装流水线的工作原理········································································31.3方案的比较选择·················································································3第2章硬件控制设计···············································································42.1PLC的选择·······················································································42.1.1PLC的结构与特点·····································································42.1.2选择PLC·················································································42.2传感器的选择···················································································5第3章软件控制设计···············································································63.1系统流程图······················································································63.2主电路接线图···················································································73.4元件清单·························································································83.5I/O接线图·······················································································93.6梯形图···························································································103.7语句表···························································································10第4章调试说明····················································································11结论····································································································12设计总结································································································13谢辞····································································································14附录·······································································································15附录一程序梯形图··············································································152附录二程序语句表··············································································18参考文献································································································211引言目前，饮料的灌装生产已经实现自动化，为了提高产品质量，缩短生产周期，适应产品迅速更新换代的要求，产品生产正向缩短生产周期、降低成本、提高生产质量等方面发展。因此，饮料厂的自动化灌装生产线中有越来越多的机器在使用先进的灌装技术来提高机器的自动化控制水平和生产效率。而应用PLC完成电气部分的控制是工业自动化电气控制的主要发展方向。本次课设主要介绍全自动灌装生产线的基本概念。全自动灌装生产线是由数台自动灌装机械经控制系统进行集中控制，并按照各自功能完成一定任务进行顺序、连续生产的一系列机器组合。通过对饮料罐装自动控制的介绍，使我们对灌装这个行业有了更深的了解，也对自动化这个名词有了进一步的了解。我国的饮料罐装自动化相对于西方发达国家来讲还有很大的差距。设备陈旧，技术落后，成为阻碍我们灌装行业发展的一个严重问题。鉴于这些问题，我国企业不断发展自身的实力，逐步朝着生产高速化、设备结构合理化、设备的多功能化、设备的绿色化、控制的智能化等方向发展出适合自己需求的产品来。本次课设就是朝着这个方向进行研究和设计。传统的饮料罐装生产线的电气设备控制系统是传统的继电器——接触器控制方式,在使用的过程中，生产工效低，人机对话靠指示灯+按钮+讯响器的工作方式，响应慢，故障率高，可靠性差，系统的工作状态、故障处理、设备监控与维护只能凭经验被动的去查找故障点。且在生产过程中容易产生二次污染，造成合格率低，生产成本增加。而自动化生产线在众多领域应用得非常广泛，其控制部分常常采用PLC控制，它使自动化生产线运行更加平稳，定位更加准确，功能更加完善，操作更加方便。为适应发展，故提出下面的PLC控制技术改造现有生产线。本文介绍了德国西门子PLCS7-200在自动化饮料罐装生产线控制系统中的应用，并从硬件和软件两方面进行了分析和研究。2第1章总体设计方案1.1系统设计程序的基本结构1.1.1系统控制结构图当按下启动开关正常工作时，通过PLC的控制下进行灌装、计数工作。当按下停止开关时，系统停止工作。图1-1系统控制结构图1.1.2饮料灌装流水线的基本结构图图1-2饮料灌装流水线的基本结构图PLC启动开关停止开关灌装设备计数31.2灌装流水线的工作原理灌装流水线的运作是通过电机和灌装设备来控制的。通过电动机的运转，带动流水线的工作。而灌装设备的开通则直接控制饮料流通。通过输入PLC软件程序，直接控制电机及流水线的运作。流水线由传感器实时监控，由PLC控制，控制准确。自动化程度高。1.3方案的比较选择检查空瓶满瓶个数时应应用液位传感器检测饮料是否灌装到要求的液位，但由于有计时器定时灌装时间，且系统设计没有此要求，综合考虑经济效益与简化系统要求，不选择液位传感器。本系统在程序编写时，采用了调用子程序，使程序模块化，简洁有序，实现了罐装的自动检测，自动灌装，自动循环，自动计数，满足了系统的要求。4第2章硬件控制设计2.1PLC的选择2.1.1PLC的结构与特点PLC的构成从结构上分，PLC分为固定式和组合式（模块式）两种。固定式PLC包括CPU板、I/O板、显示面板、内存块、电源等，这些元素组合成一个不可拆卸的整体。模块式PLC包括CPU模块、I/O模块、内存、电源模块、底板或机架，这些模块可以按照一定规则组合配置。PLC编程简介体积小，重量轻，耗电少，接线编程简单，可靠性高，反应快，可靠性高，抗干扰能力强。PLC一经出现，由于它的自动化程度高、可靠性好，设计周期短、使用和维护简便等独特优点，备受国内外工程技术人员和工商业界厂商的极大关注，生产PLC的厂商孕起。随着大规模集成电路和微处理器在PLC中应用，是PLC的功能不断得到增强，产品得到飞速发展。目前，PLC在国内外已广泛应用于钢铁、石油、化工、电力、建材、机械制造、汽车、轻纺、交通运输、环保及文化娱乐等各个行业。PLC常用程序设计语言简介方源可编程控制器程序设计语言。在可编程控制器中有多种程序设计语言，它们是梯形图语言、布尔助记符语言、功能表图语言、功能模块图语言及结构化语句描述语言等。其中梯形图程序设计语言是用梯形图的图形符号来描述程序的一种程序设计语言。是最广泛，最受欢迎的一种编程语言。它采用梯形图程序设计语言，程序采用梯形图的形式描述。这种程序设计语言采用因果关系来描述事件发生的条件和结果。每个梯级是一个因果关系。在梯级中，描述事件发生的条件表示在左面，事件发生的结果表示在后面。梯形图程序设计语言是最常用的一种程序设计语言。它来源于继电器逻辑控制系统的描述。在工业过程控制领域，电气技术人员对继电器逻辑控制技术较为熟悉，因此，由这种逻辑控制技术发展而来的梯形图受到了欢迎，并得到了广泛的应用。2.1.2选择PLCS7-200系列PLC是西门子公司20世纪90年代推出的整体式小型可编程控制器，早些时候称为CPU21X,其后的改进型称为CPU22X,其结构紧凑、功能强，焗油很高的性能价格比，在中小规