基于S7-300的芯片单元自动装配机控制系统设计

论文编号:ZD1120    论文字数:22292,页数:55

 摘     要
 随着汽车工业的迅速发展以及对装配综合自动化的要求不断提高，汽车制造业已从简单的工序间装配自动化，逐步发展到部件、整车的装配自动化。自动装配技术已经成为大批量生产的汽车工业在21世纪的重点发展领域。本论文介绍了基于S7-300的芯片单元自动装配机控制系统设计，能完成圆盘式油冷却器芯片单元的自动装配、称重。芯片单元的装配密封性直接影响圆盘式油冷却器的使用性能，因此，本次设计具有十分重要的现实意义。
 圆盘油冷却器芯片单元共包括6部分，此次设计的芯片单元自动装配机应能完成6部分的如下装配要求：按次序叠加、压合、封装、称重、计数等。另外，为提高芯片单元生产流水线的生产效率，该自动装配机应具有自检、报警功能；为满足用户不同的生产量要求，该自动装配机应可以根据用户所需的生产效率相应地调整装配速度；同时，该自动装配机应能满足人机友好要求，用户可以通过人机界面方便地进行系统调试和了解系统运行情况。装配控制系统是芯片单元自动装配机的核心部分，决定着装配机的使用性能。而本次毕业设计就是在上述背景和控制要求下展开的，基于S7-300的芯片单元自动装配机控制系统硬件主要包括：一只S7-300西门子PLC、四只S7-200西门子PLC、西门子MP277人机界面（WINCC软件组态）、6台步进电机、1台伺服电机、7台异步电机以及Micromaster系列的MM420变频器等等。另外，该控制系统在组态、编程时主要用到的软件是STEP7V5.4编程软件。
 本次系统设计以S7-300 PLC为主站，通过PROFIBUS-DP总线连接4个S7-200 PLC从站,同时S7-300 PLC还要通过PROFIBUS现场总线和人机界面及变频器通讯连接。PROFIBUS现场总线是一种国际性的、开放的、已在世界范围内得到广泛应用的现场总线。采用PROFIBUS现场总线的系统，对于不同厂家所生产的设备之间，不需要对接口进行特别的处理和转换就可以通信。因此，本次设计选用PROFIBUS现场总线非常实用，又节省设计成本。其中1个S7-200 PLC控制伺服电机，从而由伺服电机控制凸轮机构，以此最后满足自动装配机上的各机械手动作变化要求；其余3个S7-200 PLC控制6台步进电机，从而控制装配机各料杆的上升、下降动作。此外，S7-300 PLC由RS-485接口，经过PROFIBUS现场总线连接MM420，从而控制大异步电机的启动、停止与调速，最后实现自动装配机主转盘的启动、停止与调速；而用于控制转位料仓的其余6台异步电机直接由S7-300控制，能实现启动和停止。
 本次设计首先需要了解自动装配机的具体控制细节，例如：各机械手的分解动作（悬臂伸出、下降、吸盘吸气等），即可确定伺服电机相对应的具体控制要求。第二，要确定系统需要的传感输入信号数量，并确定分配好系统对应于S7-300 PLC的输入、输出信号地址。第三，根据系统控制具体要求和地址分配，协调整个系统及各控制电机子系统的逻辑关系，再根据初步列好的逻辑关系、控制要求规划流程图，然后在流程图的基础上使用STL语句表编写程序。第四，安装S7-300的编程软件STEP7V5.4，之后在STEP7V5.4编程软件上硬件组态及软件编程。最后通过调试和修改、完善程序，使系统完成圆盘油冷却器芯片六部分的装配要求。本设计重点是利用PROFIBUS总线和Wincc组态软件实现人机与S7-300的通信；在STEP7软件中进行S7-300站组态实现S7-200 PLC分别与S7-300 PLC的通讯连接；在STEP7软件中硬件组态和在MM420上参数设置实现S7-300 PLC控制大异步电机。
 
关键词：S7-300  S7-200  Profibus现场总线  Wincc  MM420

 With the rapid development of the automobile industry and the continually increasing of requirement of integrated assembly automation, automotive manufacturing is developing from simple inter-assembly automation into parts, vehicle assembly automation gradually. Automatic assembly technology has become the important area of development of volume-production of the automobile industry in the 21st century. This thesis introduces the design of the chip unit automatic assembly machine′s control system based on S7-300, which can complete the chip unit of disc oil cooler automatic assembling and weighing.The assembly leak-proof quality of the chip unit directly affect disc oil cooler's operational performance, so it is of greatly practical significance.
 The chip unit of disc oil cooler includes 6 parts, and this design of the chip unit automatic assembly machine ought to be able to complete 6 parts of following assembly assignments: superimposed in sequence, lamination, packaging, weighing, counting, etc. In addition, to increase the productivity of the production line, this automatic assembly machine should have self-checking and warning function; in order to meet different users′ requirements of production, this automatic assembly machine should be able to act according to the production efficiency when the user needs to adjust the assembly speed correspondingly. Meanwhile, this machine ought to be able to satisfy the man-machine friendly need, make user debug system and understand system operation situation conveniently through the human machine interface. The assembly control system is the core of the chip unit automatic assembly machine, which determines the assembly machine's operational performance. This graduation project is started under the above background and control requirements, and the chip unit automatic assembly machine′s control system based on S7-300 mainly includes: a S7-300 Siemens PLC, 4 S7-200 Siemens PLC, HMI (using WinCC software to configurate), 6 stepping motors, 1 servo motor, 7 asynchronous motors and MM420. Moreover, this control system mainly uses the software which called STEP7V5.4 when it needs hardware configuration, programming. This assembly control system takes S7-300 PLC as a master station, through PROFIBUS-DP connect with 4 S7-200 PLC as slave stations, and simultaneously S7-300 PLC must communicate with the human machine interface as well as MM420 through PROFIBUS. PROFIBUS is an international, open, have been widely used worldwide fieldbus. The equipments produced by different manufacturers of the equipment can be communicated without special handling and transformation when using PROFIBUS in the system. Therefore, this design selects the PROFIBUS to be practical, and decrease design cost as well. A S7-200 PLC controls the servo motor, thus by the servo motor control cam gear, so finally satisfies on various manipulators of the automatic assembly machine to act the changing movement. Other 3 S7-200 PLC control 6 stepping motors, thus control the up and down of the assembly machine's six material poles. In addition, S7-300 PLC connects through PROFIBUS with MM420 by the RS-485 interface, to control the start and speed of the large asynchronous motor, which finally makes the automatic assembly machine main dividing plate start, stop and speed. And the other 6 asynchronous motors which used in controlling the six storehouses are controlled directly by S7-300 to start and stop.
 Before this design, firstly we need to understand the automatic assembly machine's concrete control details, for example: Various manipulators' decomposition movement (bracket stretches out, drop, sucker inspiration and so on), then determine the servo motor′s correspondingly concrete control requirements. Secondly, we must make certain the input signal quantity that the system needs, and determine how to assign a good system for the S7-300 PLC input and output signal addresses correspondingly. Thirdly, according to the systems control specific requirements and the allocation, we should coordinate the overall system and each control electrical machinery subsystem's logical relation, then plan flow chart according to the preliminary row good logical relation and the control requirements and use the STL writing program under the flow chart foundation. Fourthly, we need to install S7-300 programming software STEP7V5.4, then take the hardware configuration and software programming on STEP7V5.4 programming software. Finally, we can make the control system complete the chip unit six parts′ assembly requirements through program debugging,   revision and consummation. This design focuses on realizing the correspondence between human machine interface and S7-300 PLC using PROFIBUS and WinCC configuration software; carring on the S7-300 station configuration in STEP7 software to realize S7-200 communicate separately with the S7-300; making hardware configuration in the STEP7 and setting parameters in MM420 to control the large asynchronous motor by S7-300 PLC.
 
Keywords: S7-300  S7-200  PROFIBUS  WinCC  MM420

 目  录
摘  要 I
Abstract III
目  录 V
第一章  绪 论 1
1.1  选题的背景与意义 1
1.1.1 自动装配技术发展趋势 1
1.1.2 PROFIBUS 现场总线技术 1
1.1.3 S7-300 PLC的应用现状 2
1.1.4 监控组态软件的应用现状及趋势 3
1.2  系统概述和研究方法 3
1.3  论文设计任务 4
1.4  本章小结 4
第二章  系统整体方案 5
2.1  S7-300硬件概述 5
2.1.1 S7-300的硬件基本结构 5
2.1.2 S7-300的通讯接口 7
2.2  S7-300的编程软件——STEP7 V5.4 8
2.2.1 STEP7的使用 8
2.2.2  STEP7的编程语言 10
2.3  S7-300与 S7-200的通讯 11
2.4  系统总体设计 15
2.4.1 本系统硬件设计 15
2.4.2 控制系统流水线动作细分 16
2.4.3 系统总体流程设计 19
2.4.4 初始化巡检流程图 19
2.5  本章小结 20
第三章  人机界面和S7-300的通讯 21
3.1  工控组态软件WINCC 21
3.2  人机界面和S7-300的通讯实现方法 21
3.3  本章小结 25
第四章  伺服电机控制子系统 26
4.1  伺服电机的控制要求 26
4.1.1 伺服电机的转角控制 26
4.1.2 S7-300与S7-200的通信约定 26
4.2  伺服电机的调试流程图 27
4.3  伺服电机的调试部分程序举例 28
4.4  本章小结 30
第五章  异步电机控制子系统 31
5.1  异步电机控制要求 31
5.1.1 大异步电机控制规划 31
5.1.2 小异步电机控制规划 31
5.2  S7-300与MM420的PROFIBUS-DP通讯 31
5.2.1 组态 MICROMASTER 4 31
5.2.2 在MICROMASTER上设置参数 32
5.2.3 使MM420准备运行 33
5.2.4 由PLC控制MM420 33
5.3  异步电机控制系统调试流程图 34
5.4  异步电机调试控制系统程序举例 34
5.5  伺服、异步联动调试流程图 36
5.6  本章小结 37
第六章  步进电机控制子系统 38
6.1  步进电机的简介 38
6.2  步进电机的控制要求 38
6.3  S7-300控制步进电机流程图 39
6.4  本章小结 39
第七章  全自动运行控制系统 40
7.1  全自动运行时的控制要求 40
7.2  全自动运行时的控制流程图 40
7.3  全自动运行时伺服、异步同步联动 42
7.4  本章小结 44
第八章 总结 45
参考文献 47
致  谢 48

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