The main steps in the planning and commissioning of the programmable manipulator application system
(1) In-depth understanding and analysis of the process conditions and control requirements of the controlled target
a. The controlled target is the controlled machinery, electrical equipment, production line or production process.
b. The control requirements mainly refer to the fundamental mode of control, the actions that should be completed, the composition of the automatic operation cycle, the necessary protection and interlocking, etc. For more complex control systems, the control tasks can also be divided into several independent parts, which can be simplified and conducive to programming and debugging.
(2) Confirm the I/O device
According to the functional requirements of the controlled target for the PLC control system, confirm the user input and output equipment required by the system. Commonly used input devices include buttons, selection switches, travel switches, sensors, etc., and commonly used output devices include relays, contactors, indicator lights, solenoid valves, etc.
(3) Select the appropriate PLC type
According to the confirmed user I/O equipment, count the number of required input signals and output signals, and select the appropriate PLC type, including the selection of models, capacity, I/O modules, power modules, etc.
(4) Allocate I/O points
Assign the input and output points of the PLC, compile the input/output distribution table or draw the wiring diagram of the input/output terminals. Next, PLC program planning can be carried out, and together with the planning and on-site construction of the control cabinet or operating station.
(5) Planning and application of the system ladder diagram program
According to the operation function diagram or status flow chart, etc., the ladder diagram is planned, that is, programming. This step is the core operation of the whole application system planning, and it is also a more difficult step, to plan the ladder diagram, first of all, we must be very familiar with the control requirements, and we must have a certain practical experience in electrical planning.
(6) Enter the program into the PLC
When using a simple programmer to input a program into a PLC, the ladder diagram needs to be converted into an instruction mnemonic for input. When programming on a computer using the programmable manipulator's auxiliary programming software, the program can be downloaded to the PLC via the connecting cable of the upper and lower computers.
(7) Conduct software quizzes
Once the program has been entered into the PLC, a test assignment should be performed first. Because in the process of program planning, there will inevitably be omissions. Therefore, before connecting the PLC to the field equipment, it is necessary to carry out a software test to eliminate errors in the program, and also lay a good foundation for the whole debugging and shorten the whole debugging cycle.
(8) Debugging of the whole application system
After the completion of PLC software and hardware planning and control cabinet and on-site construction, the online debugging of the whole system can be carried out. If there are many steps in the control program, you can debug them in sections first, and then connect them to the general adjustment. Problems found in debugging should be eliminated one by one until debugging is successful.
(9) Preparation of skills documents
The system skills document includes manuals, electrical schematic diagrams, electrical layout diagrams, electrical component schedules, and PLC ladder diagrams.
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